CleanTrack 1000 B - Manual - Insatech Marine

Brannstrom Sweden AB

Uddevallagatan 14 416 70 Gothenburg, Sweden

Tel: +46 (0)31 195600 Fax: +46 (0)31 197790

Email: [email protected]

Operations and Technical manual for Oil Discharge Monitoring Equipment

CleanTrack 1000 B (Revision 2.20xd for Software version 2.20x)

Brannstrom Sweden AB CleanTrack 1000B - Rev 2.20xd, 2019 Page 2 of 232

Content 1. Introduction .......................................................................................................................................... 5 2. Important Notes ................................................................................................................................... 6

2.1. Component Replacement/Repair .......................................................................................................... 6 2.2. Disclaimer and Conditions ................................................................................................................... 6 2.3. Main news in software version 2.20x compared to version 2.12. ......................................................... 6 2.4. Updates in this manual. ........................................................................................................................ 7

3. Specification .......................................................................................................................................... 7 3.1. Description ........................................................................................................................................... 7

3.1.1. Function and main parts ..................................................................................................... 7 3.1.2. Measuring principle ........................................................................................................... 8

3.2. Scope of Supply and System Supplies .................................................................................................. 9 3.2.1. Parts always included in the Analyzing unit ...................................................................... 13

3.3. System Interfaces.................................................................................................................................. 14 4. Installation ............................................................................................................................................ 15

4.1. Computer Unit ...................................................................................................................................... 15 4.1.1. Mechanical ......................................................................................................................... 15 4.1.2. Electrical ............................................................................................................................ 15

4.2. Converting Unit .................................................................................................................................... 16 4.2.1. Mechanical ......................................................................................................................... 16 4.2.2. Electrical ............................................................................................................................ 16

4.3. Analyzing Unit ..................................................................................................................................... 17 4.3.1. General drawings ............................................................................................................... 17 4.3.2. Mechanical ......................................................................................................................... 17 4.3.3. Electrical ............................................................................................................................ 17 4.3.4. Inlet probe and Outlet stub ................................................................................................. 18 4.3.5. Piping of Sample Inlet and Outlet ...................................................................................... 19 4.3.6. Piping for Fresh water (Option) ......................................................................................... 19 4.3.7. Piping for Air motor (Air motor option only) .................................................................... 20

4.4. Flow meter and Speed log .................................................................................................................... 21 4.4.1. Flow meter general ............................................................................................................ 21 4.4.2. BRANNSTROM standard flow transmitter. ...................................................................... 21 4.4.3. Speed log general ............................................................................................................... 21

4.5. Paper Printer ......................................................................................................................................... 22 4.6. Response time calculations ................................................................................................................... 22 4.7. First Start up Checklist ......................................................................................................................... 23 4.8. Pressure alarm settings ......................................................................................................................... 24 4.9. Zener Barrier Instructions and Replacement ........................................................................................ 25 4.10. Measuring Cell Instructions and Replacement ................................................................................... 30

4.10.1. Measuring Cell replacement (CTB10032) ....................................................................... 33 4.11. Calculations on intrinsically safe arrangements .................................................................................. 36

5. Start/Stop procedure ............................................................................................................................ 38 5.1. General information before Start-up ..................................................................................................... 38 5.2. Start-up procedure ................................................................................................................................ 38 5.3. Close down procedure .......................................................................................................................... 39 5.4. Closing down for a longer time or preserving for sub-zero conditions ................................................. 39

6. Menu operations ................................................................................................................................... 41 6.1. Main Menu and Top of Page indications .............................................................................................. 41 6.2. Edit Numeric values ............................................................................................................................. 42 6.3. Keys ...................................................................................................................................................... 42 6.4. Password ............................................................................................................................................... 43 6.5. Measuring Cell - Indications and Keys ................................................................................................. 44

7. Menu layout .......................................................................................................................................... 45 7.1. Main Menu ........................................................................................................................................... 45

7.1.1. Start page ........................................................................................................................... 45 7.2. Operation .............................................................................................................................................. 46

7.2.1. Running ............................................................................................................................. 46 7.2.2. Running Settings ................................................................................................................ 47

7.2.2.1. "Discharge line" 47 7.2.2.2. "Oil type" 48

7.2.3. Manual Override ................................................................................................................ 51 7.2.4. Status ................................................................................................................................. 52

7.3. Alarm Table .......................................................................................................................................... 53 7.4. Recorded data ....................................................................................................................................... 54

7.4.1. Recorded data examples .................................................................................................... 55 7.5. USB ...................................................................................................................................................... 56

7.5.1. USB-Memory stick ............................................................................................................ 56 7.5.2. Save Printouts on USB stick .............................................................................................. 58

7.6. On-board Test ....................................................................................................................................... 59 7.7. Measuring Cell Check/Calibration ....................................................................................................... 63


7.7.1. Zero Calibration Status ...................................................................................................... 63 7.7.2. Zero Calibration Prepare .................................................................................................... 64 7.7.3. Zero Calibration Take Zero ............................................................................................... 65 7.7.4. Replace Measuring Cell ..................................................................................................... 66

7.8. Setup of parameters .............................................................................................................................. 67 7.8.1. Line of discharge ............................................................................................................... 67 7.8.2. ZF1 (Zener barrier flow input 1) ........................................................................................ 68 7.8.3. ZF2 .................................................................................................................................... 68 7.8.4. CVF ................................................................................................................................... 68 7.8.5. Pressure .............................................................................................................................. 69

7.8.5.1. Static Pressure/Water function 69 7.8.6. Motor (Optional Extended Converting unit I/O PCB) ...................................................... 70 7.8.7. Speed ................................................................................................................................. 70 7.8.8. System Configuration, Standard ........................................................................................ 71 7.8.9. System Configuration, Alarms&Extras ............................................................................. 71

7.9. Computer .............................................................................................................................................. 73 7.9.1. USB-Memory stick ............................................................................................................ 73 7.9.2. Real Time Clock ................................................................................................................ 73 7.9.3. IP-address .......................................................................................................................... 74 7.9.4. Touch Screen Calibration .................................................................................................. 74

7.10. System Check ..................................................................................................................................... 75 7.10.1. Main ................................................................................................................................. 75 7.10.2. Test .................................................................................................................................. 75 7.10.3. GPS (NMEA 0183 receiver) ............................................................................................ 76 7.10.4. Paper Printer _(Optional) ................................................................................................. 76 7.10.5. Expiry (Trial period) ...................................................................................................... 77 7.10.6. Power (Computer unit Power supply) ............................................................................ 77 7.10.7. CUIO (Computer unit I/O PCB) .................................................................................... 78 7.10.8. CVCT/Standard (Converting unit I/O PCB) .................................................................. 78 7.10.9. CVCT/Extended (Optional Extended Converting unit I/O PCB) ................................... 79 7.10.10. ZBCT (Converting unit Zener Barrier PCB) ................................................................ 79 7.10.11. MC (Measuring Cell) ................................................................................................... 80 7.10.12. External Modbus RTU (Optional CUIO) ..................................................................... 80

7.11. Approvals ........................................................................................................................................... 81 8. Fault-finding ......................................................................................................................................... 82

8.1. Malfunction of Computer/Converting unit ........................................................................................... 82 8.2. List of displayed alarms ........................................................................................................................ 82 8.3. System file errors .................................................................................................................................. 83 8.4. System communications errors ............................................................................................................. 84 8.5. External sensor alarms .......................................................................................................................... 85 8.6. Measurement alarms ............................................................................................................................. 86 8.7. Measurement sample alarms ................................................................................................................. 86 8.8. Paper Printer alarms ............................................................................................................................. 87 8.9. Extended Converting unit Motor alarms (Optional) ............................................................................. 88 8.10. Miscellaneous Sample pump and Overboard Valve alarms. ............................................................... 88 8.11. Indications on PCB's ........................................................................................................................... 90

8.11.1. Computer unit I/O PCB indications ................................................................................. 90 8.11.2. Converting unit I/O PCB indications ............................................................................... 90 8.11.3. Extended Converting unit I/O PCB indications (Optional) .............................................. 91 8.11.4. Zener barrier PCB indications.......................................................................................... 91

9. Maintenance, Spare parts and Consumables ..................................................................................... 92 9.1. Software upgrading .............................................................................................................................. 92 9.2. Battery replacement .............................................................................................................................. 92 9.3. Saving Printouts and Settings on a USB memory stick ........................................................................ 92 9.4. Periodic Checks and Servicing ............................................................................................................. 92 9.5. Verification of accuracy and access to restricted parts ......................................................................... 93 9.6. Cleaning of Inlet Filter ......................................................................................................................... 93 9.7. Sample Pump Shaft seal oil refilling .................................................................................................... 93 9.8. Spare parts ............................................................................................................................................ 94

9.8.1. Computer Unit ................................................................................................................... 94 9.8.2. Converting Unit ................................................................................................................. 94 9.8.3. Analyzing Unit................................................................................................................... 94 9.8.4. Sample pump ..................................................................................................................... 94

9.8.4.1. Ex. motor Sample pump, SPP-100 94 9.8.4.2. Bulkhead mounted Sample pump, Nikuni 32MED22 94 9.8.4.3. Bulkhead mounted Sample pump, Matre P06 94 9.8.4.4. Air motor Sample pump, Speck Y2951 94

9.8.5. Fuses .................................................................................................................................. 94 9.9. Recommended Spare parts ................................................................................................................... 95 9.10. Consumables ...................................................................................................................................... 95 9.11. Storage before installation .................................................................................................................. 95

10. Figures and Drawings ........................................................................................................................ 96


10.1. Computer Unit .................................................................................................................................... 97 10.2. Converting Unit .................................................................................................................................. 100 10.3. Analyzing Unit ................................................................................................................................... 104

10.3.1. Analyzing Unit skid with Ex. motor Sample pump ......................................................... 104 10.3.2. Analyzing Unit with external Sample pump .................................................................... 107 10.3.3. Analyzing Unit with Freestanding items for External Sample pump ............................... 112 10.3.4. Analyzing Unit with Air motor Sample pump ................................................................. 114

10.4. SPP-100 Sample pump with Ex. Motor .............................................................................................. 119 10.5. Nikuni Sample pump for Bulkhead mounting .................................................................................... 121 10.6. Matre Sample pump for Bulkhead mounting ...................................................................................... 124 10.7. Connection box ................................................................................................................................... 126 10.8. Measuring Cell replacement ............................................................................................................... 128 10.9. GA-plans ............................................................................................................................................ 129

10.9.1. Partnames of typical arrangement .................................................................................... 129 10.9.2. GA-plan with Ex. motor Sample pump ............................................................................ 130 10.9.3. GA-plan with bulkhead penetrating Sample pump .......................................................... 133 10.9.4. GA-plan with Air motor Sample pump ............................................................................ 135 10.9.5. GA-plan with pilot controlled Air motor Sample pump................................................... 137

10.10. Electrical ........................................................................................................................................... 138 10.10.1. Electrical cable diagram for electrical Ex. motor sample pump ..................................... 138 10.10.2. Electrical cable diagram for bulkhead mounted sample pump ....................................... 139 10.10.3. Electrical cable diagram for air motor sample pump ..................................................... 140 10.10.4. Internal cable diagram for electrical sample pump motor .............................................. 141 10.10.5. Internal cable diagram for Extended SPP-100 sample pump motor (Optional) ............. 142

10.11. Sample probes .................................................................................................................................. 143 10.11.1. Sample probes installation arrangements 1” .................................................................. 143

10.12. Flow meter ........................................................................................................................................ 145 11. Approval Certificates ......................................................................................................................... 148

11.1. Certificate: MED-D ............................................................................................................................ 148 11.2. Type Approval, DNV ......................................................................................................................... 150 11.3. Type Approval, Germany ................................................................................................................... 154 11.4. IMO Certificate, CCS ......................................................................................................................... 158 11.5. Type Approval, CCS .......................................................................................................................... 160 11.6. Type Approval, NK ............................................................................................................................ 163 11.7. Type Approval, RMRS ....................................................................................................................... 164

12. ATEX Certificates and Instructions ................................................................................................. 166 12.1. Declaration of Conformity .................................................................................................................. 166 12.2. ATEX Certificate Zener Barrier PCB ................................................................................................. 169 12.3. ATEX Certificate Measuring Cell ...................................................................................................... 174 12.4. Pressure transmitter, Danfoss ............................................................................................................. 178 12.5. Pressure transmitter, Siemens ............................................................................................................. 185

12.5.1. Declaration of Conformity ............................................................................................... 185 12.5.2. ATEX Certificate ............................................................................................................. 187

12.6. Flow meter, Siemens .......................................................................................................................... 190 12.7. Flow meter, Fuji ................................................................................................................................. 198 12.8. Sample Pump, SPP-100 with Elprom explosion proof motor ............................................................. 201

12.8.1. Elprom instructions .......................................................................................................... 201 12.8.2. Elprom Certificate, EPT 17 ATEX 2588 X ..................................................................... 205 12.8.3. Elprom Certificate, EUM1 10 ATEX 0350 ..................................................................... 209 12.8.4. Hummel Cable Gland Certificate, DEKRA 12ATEX0139 X .......................................... 226

12.9. Sample Pump, Speck pump with Gast air motor ................................................................................ 228 13. Appendix, Work shop test and Calibration Certificate .................................................................. 229 14. Project specific drawings and data sheets ........................................................................................ 231


1. Introduction The Oil Discharge Monitoring System, CleanTrack 1000 B, has been designed to provide means of monitoring, recording and controlling the ballast discharge in accordance with the requirements in Resolution MEPC.108(49) as amended by Resolution MEPC.240(65) and is also approved for Bio- fuel blends in accordance with MEPC.1/Circ.761 as revised. The requirements of the MARPOL Convention are that all oil tankers with a gross tonnage of 150 GRT and above must have an oil discharge monitoring and control system installed with an automatic overboard valve control system. The requirements in Resolution MEPC.108(49) as amended apply to tankers with a date of keel laying or equivalent stage of construction of 1st of January 2005 or later. Tankers with a keel laid before 1st of January 2005 should comply either with these new or the older Guidelines and Specifications. Discharge limits are set at 30 liters per nautical mile (fixed) and a total discharge limit in liters (to be set by the user) equaling 1/30,000 part of the particular cargo of which the residue formed a part. The unit has also a 15 ppm mode intended for clean ballast. The recording device is formatted electronically as mentioned in MEPC.108(49) chapter 6.9.1. Recorded data is stored in a non-volatile memory and can hold approximately 3,000,000 printouts. Optionally a paper printer can also be installed in the computer unit. In addition to this equipment manual, the ship builder, installation contractor or whoever is commissioned by the ship owner to do it, will prepare ship specific documentation in the form of a manual covering the parts not covered by this equipment manual. For details see MEPC.108(49) sections 9.3 – 9.8 and 11.1.4 – 11.1.6.


2. Important Notes

2.1. Component Replacement/Repair Placement of security seals on critical components is to prevent tampering by unauthorized personnel. Replacement or repair of this equipment should only be carried out under guidance of Brannstrom Sweden AB.

2.2. Disclaimer and Conditions All information provided by Brannstrom Sweden AB about this equipment is given in good faith and is based on the best knowledge available at the particular time. No responsibility is, however, assumed for possible inaccuracies or omissions. The content of this manual may be copied as required for operational use on the vessel in which the equipment is installed. This Manual must not be copied, in full or in part, for disclosure to third part. The software incorporated in the equipment is furnished on a strictly “as is” basis. The software is proprietary to Brannstrom Sweden AB. The disclosure of the software coding is not allowed. The software may not be copied in whole or part.

2.3. Main news in software version 2.20x compared to version 2.12.

1. It can be upgraded to handle 5 more bio-fuel blends to a total of 10 bio-fuel blends. 2. It listens to more GPS NMEA 0183 sentences, in addition to RMC also GLL, GGA and VTG. 3. It supports version 4.10 of GPS NMEA 0183 sentences. 4. Manual “Oil concentration” selection disables start of the sample pump and ignores readings from the

Measuring cell. 5. It can monitor feedback from the sample pump start/stop contactor. 6. It can monitor feedback from a sample pump motor disconnector switch. Switch is not in scope of delivery. 7. It has an optional alarm for freezing risk of water in the Measuring cell. 8. It has programmable feedback timeout for two overboard valves. 9. If the converting unit is fitted with the optional sample pump motor heating to avoid moisture in “StandBy”

mode, it can control the heating and monitor the motor voltage, current, cos φ, frequency, and overheating. Documentation for this feature is delivered with special orders only.

10. For specially built computer units with an optional Modbus RTU serial communication channel, it can communicate with the cargo control system. Documentation for this feature is delivered with special orders only.

11. For specially built computer units with an optional NMEA alike serial communication port it can send printout data to a listener. Documentation for this feature is delivered with special orders only.

12. It has settings for optional control of the slop tank valve separately using the relay output normally intended to control the overboard valve no. 2. Documentation for this feature is delivered with special orders only.

13. Automatically recorded data compressed from 9 lines to 6 lines (MEPC.108(49) Chapter 6.9.2). 14. Naming of oil types closer to naming in applicable IMO resolutions. 15. Flow alarms are no longer generated while flow is in manual mode (“Manual Flow” is activated).

2.203 16. For optional extended converting unit only: New setting “Extended-NoLim” in property

“ConvertingUnitType” with limited motor alarms. 2.204

17. For optional extended converting unit only: “Disable Motor check” disables motor windings ptc alarms also. Voltage of an activated heater is shown on top screen indications, “StandBy” -> “StandBy, xxV”.


2.4. Updates in this manual. A detail information about changes in this manual compared to the previous manual, version 2.12k, is not meaningful as there are too many details, computer menus and certificates that are changed, removed or added. Instead the major functional changes have been listed above. Version 2.20x -> 2.20xc:

1. New “Declaration of Conformity”, issued 2019-01-02. Chapter 12.1. Declaration of Conformity page 166. 2. Upgrade of details changed in software version 2.204. Changes for optional extended converting unit only.

Version 2.20xc -> 2.20xd: 1. New “Declaration of Conformity”, issued 2019-01-02. Chapter 12.1. Declaration of Conformity page 166.

3. Specification

3.1. Description Type CleanTrack 1000 B Application Oil Discharge Monitoring and Control System for Oil Tankers in

accordance with MEPC.108(49) as amended by Resolution MEPC.240(65), approved for Crude oils and Petroleum products as well as for 10 types of Bio-fuel blends in accordance with MEPC.1/Circ.761 as revised.

Range 0 - 1000 ppm Accuracy According to MEPC.108(49) Sample Flow rate 240 liters/hour to 900 liters/hour depending on sample pump model. Clean water connection (optional): Flow rate Intermittently 200 to 600 liters/hour depending on sample pump model and

water pressure. Clean water is only used at Discharge Start and Stop. Approximately 6-20 liters per Start/Stop (when applicable). Pressure max. 5 bar

min. 0.5 bar higher than the pressure in the overboard line at the sample outlet connected point.

3.1.1. Function and main parts Purpose and function of the CleanTrack 1000B. On an oil tanker the CleanTrack 1000B monitors and controls the discharge of oily water from a slop tank to the sea according to MARPOL Annex I regulation 34, and it is specified in detail in IMO resolution MEPC.108(49). When water is pumped from the slop tank into the discharge pipe, it can be diverted either back to the slop tank via a slop tank valve, or over board to the sea via an overboard valve. Normally the overboard valve is closed and the slop tank valve is open, diverting the water back to the slop tank. The water can be diverted to the sea only when the CleanTrack 1000B enables opening of the overboard valve. The CleanTrack 1000B samples water from the discharge pipe and measures the oil content of it. The CleanTrack 1000B also receives info about the ship’s speed (from the ship’s speed log or the GPS), the water flow rate from a flow meter in the discharge pipe, and the ship’s position (from the GPS). Based on this info, the CleanTrack 1000B calculates the instantaneous discharge rate of pure oil per nautical mile, and the total quantity of pure oil discharged. The instantaneous rate of discharge of oil content must not exceed 30 liters per nautical mile, and the total quantity of oil discharged into the sea must not exceed 1/30000 of the total quantity of the particular cargo of which the residue formed a part. When start pumping water from the slop tank, the water is diverted back to the slop tank. When the CleanTrack 1000B has determined that none of the above discharge limits are exceeded, it enables diverting the water into the sea. When any of the discharge limits are reached, or there is a failure of the CleanTrack 1000B or any of the external signals are missing, the overboard valve is automatically closed and the slop tank valve is opened. These events and the corresponding ship’s position are recorded by the CleanTrack 1000B.


The unit consists of 4 main parts: A Computer unit intended to be installed in the cargo control room or in an equivalent nonhazardous area. The computer unit controls and receives data from the other CleanTrack components. This information is treated for computing and control purposes and is documented in the unit`s memory required by IMO. The other parts of the system are controlled from the computer unit. It also receives positioning data from the GPS. This computer unit contains the parts and functions defined by IMO resolution MEPC.108(49) as the “Control section”, “Control unit”, “Discharge interlock” and “Overboard discharge control”. A Converting unit intended to be installed in the engine room or other suitable nonhazardous area. The converting unit receives and transmits electrical signals from the analyzing unit to the computer unit. It contains electrical power supply and zener barriers for the analyzing unit, a 2 wire 4 – 20 mA input for the pressure transmitter and two, 2 wire 4 – 20 mA inputs for flow meters. The sample pump and optional fresh water flushing control is also controlled by the converting unit. An Analyzing unit intended to be installed in the pump room or other hazardous cargo area. The analyzing unit contains the measuring cell and the pressure transmitter that monitors the sample flow through the measuring cell. The pressure transmitter measures the pressure on the outlet of the sample pump and is used to protect the pump from blockages or starvation. The distance between the sampling probes and the analyzing unit should be as short as possible. The maximum distance depends on the sample pump and the pipe diameter. This analyzing unit corresponds to the “Oil content meter” as defined by IMO resolution MEPC.108(49). A Sample pump of impeller type, to be installed close to the analyzing unit and normally in the pump room. The sample pump prepares and feeds the sample from the overboard line to the measuring cell. The sample pump can be of 3 main types. Depending on type is can be mounted in the hazardous area or on the bulkhead between the engine room and the pump room.

1) With an air driven motor for mounting in hazardous area zone 1. 2) With a flameproof Exd motor for mounting in hazardous area zone 1. 3) Bulkhead mounted type with the electrical motor in the non-hazardous area (E/R) and the pump

in the hazardous area (P/R) zone 0 or zone 1. 3.1.2. Measuring principle The measuring principle of the CleanTrack 1000B is based on a combination of light transmitted and light scattering in four different angles. The sample water stream is homogenized in the sample feed pump and is passed through a quartz glass tube where it is exposed to a light beam. The light transmitted and scattered in the selected angles is dependent on the type and amount of contaminates in the water stream. Signals from non-oil contaminants can be compensated for due to their different light scattering characteristics.


3.2. Scope of Supply and System Supplies The CleanTrack 1000B parts:

1. Computer unit, 1 pc. 2. Converting unit, 1 pc.

a. Standard - for all electric motor sample pumps. b. Standard Air - for air motor sample pump. c. Extended - optional and for SPP-100 sample pump only.

3. Analyzing unit, 1 pc. a. Skid with sample pump having explosion proof electric motor. b. For external sample pump.

1. Compact cabinet. 2. Freestanding items with measuring cell hood.

c. Built in sample pump having air motor. 4. Sample pump, 1pcs

a. Explosion proof electric motor, normally mounted on skid in pump room. b. Electric motor mounted on bulkhead, engine room/pump room. c. Air motor, normally mounted inside analyzing unit.

5. Flow meter(s) – (Normally yard supply, supplied on request). 6. Sample probe(s) including valves and inlet filter – (Normally yard supply, supplied on

request). 7. Overboard valve and Slop tank valve – (Normally yard supply, supplied on request). 8. Pneumatic control box for Overboard and Slop tank valves – (Normally yard supply,

supplied on request). 9. Miscellaneous.

1. Computer unit: Voltage 85-265 VAC Frequency 50/60 Hz Consumption 30 W Ingress Protection IP42 Ambient Temp. 5 - 50 °C Weight ~7 kg Dimensions approx. 370 x 210 mm


2. Converting unit: 2.a. Standard - for all Electric Motor Sample Pumps: (door not displayed) Voltage 380 or 440 VAC 3-phase ±10%, transient ±20% Frequency 50/60 Hz Consumption 120 W (exclusive pump) Ingress Protection IP54 Ambient Temp. 5 - 50 °C Weight ~14 kg Dimensions approx. 550 x 360 x 130 mm Color RAL-7035 Motor protection relay Suitable for sample pump motor current. Or; 2.b. Standard Air - for Air Motor Sample Pump: (door not displayed) Voltage 110 or 220 VAC ±10%, transient ±20% Frequency 50/60 Hz Consumption 120 W Ingress Protection IP54 Ambient Temp. 5 - 50 °C Weight ~14 kg Dimensions approx. 550 x 360 x 130 mm Color RAL-7035 Or; 2.c. Extended - Optional for SPP-100 Sample Pump only: (door not displayed) Voltage 380 or 440 VAC 3-phase ±10%, transient ±20% Frequency 50/60 Hz Consumption 120 W (exclusive pump) Ingress Protection IP54 Ambient Temp. 5 - 50 °C Weight ~14 kg Dimensions approx. 550 x 360 x 130 mm Color RAL-7035 Motor protection relay Suitable for SPP-100 sample pump motor current. Please note, this is an optionally equipped converting unit and it can only be used together with the SPP-100 sample pump. It has the capability of heating the sample pump motor with about 15 W and it can also monitor the voltage between 2 phases, current of all 3 phases, the power factor and the resistance of the PTC resistors in the motor windings. If unit is powered through a frequency converter measurement might be faulty. For setting, see chapter 7.8.9. System Configuration, Alarms&Extras page 71. See also drawing CTB10003 sheet 4 of 4, Converting Unit page 103.


3. Analyzing unit: 3.a. Skid with Sample Pump, Ex. proof Electric Motor: (Voltage is supplied via converting unit) Voltage 380 or 440 VAC 3-phase Frequency 50/60 Hz Power Consumption 0.66 kW Sample flow 600 l/h (nominal) Sample Temp. 0 - 65 ºC Ambient Temp. -20 - +55 ºC Weight ~35 kg Dimensions approx. 350 x 410 x 250 mm Color RAL-7035 See 4.a. below for more information about the Sample pump Or: 3.b. For External Sample Pump: (door not displayed) 3.b.1. Compact Cabinet: Sample flow 240-900 l/h (depending on sample pump) Sample Temp. 0 - 65 ºC Weight ~10 kg Ingress Protection: IP56 Ambient Temp. -25 - +55 ºC1 Dimensions approx. 350 x 410 x 250 mm Color RAL-7035 or: 3.b.2. Freestanding items with measuring cell hood: (Intended for retrofit installation inside an existing cabinet) (Existing sample pump and pressure transmitter to be used) Sample flow 240-900 l/h (depending on sample pump) Sample Temp. 0 – 65 ºC Ingress Protection IP56 Ambient Temp. -25 - +55 ºC Or: 3.c. With built in Sample Pump, Air Motor: (door not displayed) Air pressure 5.2 bar Air consumption ~30 Nm³/h Sample flow 240 l/h (nominal) Sample Temp. 0 - 65 ºC Weight ~18 kg Ingress Protection: IP56 Ambient Temp. +1 - +40 ºC1 Dimensions approx. 350 x 410 x 250 mm Color RAL-7035 See 4.c. below for more information about the Sample pump

1 If sample temperature is higher than the ambient temperature limit the limit becomes lower or cabinet should be ventilated.


4.a. Sample pump SPP-100 with Explosion proof electric motor: Supply voltage 400 VAC,50 Hz / 440 VAC,60 Hz 3-phase Current 1.4 A / 1.5 A Power Consumption 0.55 kW / 0.66 kW Cos φ 0.78 Speed 2840 rpm / 3400 rpm Sample flow 600 l/h (nominal) Sample temp. 0 - +65 ºC Ambient temp. -20 - +55 ºC Ingress Protection IP66 Weight ~11.5 kg Dimensions approx. 300 x 140 x 200 mm Ex. class II 1 G Ex d IIC T4 Ga Details See chapter 10.4. SPP-100 Sample pump with Ex. Motor page 119

and 12.8. Sample Pump, SPP-100 with Elprom explosion proof motor page 201. 4.b. Sample pump Nikuni 32MED22/Matre P06 for Bulkhead mounting: Note that different motors might be used for these pumps over and technical data might differ slightly from the ones given below. Please read the marking plate of the actual motor. Supply voltage 380-420 VAC,50 Hz / 440-480 VAC,60 Hz 3-phase Current 4.53 A / 4.74 A Power Consumption 2.2 kW / 2.53 kW Cos φ 0.86 Speed 2850 rpm / 3440 rpm Sample flow 900 l/h (nominal) Sample temp. 0 - +65 ºC Ambient temp. 0 - +40 ºC Ingress Protection IP55 Weight ~59 kg Dimensions approx. 600 x 280 x 410 mm Details Nikuni: See chapter 10.5. Nikuni Sample pump for Bulkhead mounting page 121. Matre: See chapter 10.6. Matre Sample pump for Bulkhead mounting page 124. 4.c. Sample pump Speck Y-2951 with Air driven Gast motor: Air pressure 5.2 bar Air consumption ~30 Nm³/h Sample flow 240 l/h (nominal) Sample Temp. 0 - +65 ºC Ambient Temp. +1 - +40 ºC2 Ingress Protection: IP56 Weight ~2.2 kg Dimensions approx. 190 x 80 x 80 mm Ex. class II 2 GDc T4 Details See chapter 12.9. Sample Pump, Speck pump with Gast air motor page 228.

2 If sample temperature is higher than the ambient temperature limit the limit becomes lower or cabinet should be ventilated.

mailto:1.5A@440VAC,60Hz

mailto:1.5A@440VAC,60Hz


3.2.1. Parts always included in the Analyzing unit Measuring Cell (including its mounts): Design Pressure 10 bar Ingress Protection IP56 Ambient Temp. -25 - +55 ºC Sample Temp. 0 - 65 ºC Orifice on outlet Ø 2.5, 3.5 or 4.3 mm (Speck Y-2951: Ø2.5 mm; SPP-100: Ø3.5 mm; Nikuni 32MED22/Matre P06 Ø4.3 mm) Ex. class II 1 G Ex ia IIC T4 Ga Tamb -40ºC - +60 ºC Connection Box, (for intrinsically safe circuits only): Ingress Protection IP56 Ambient Temp. -25 - +55 ºC Pressure transmitter: Maker Siemens Type 7MF1567–3CB01-1AA1 Ingress Protection IP65 Ambient Temp. -25 - +85 ºC Sample Temp. 0 - +120 ºC Measuring range 0-16 bar (4-20ma, 2-wire 24VDC loop powered) Sample connection G½” mail thread Length approx. 115 mm Ex. Class II 1/2 GD Ex ia IIC T4 Ga/Gb Alternative pressure transmitter:

Maker Danfoss Type MBS 4251-2211-1AB08 Ingress Protection IP65 Ambient Temp. -40 - +100 ºC Sample Temp. 0 - +125 ºC Measuring range 0-16 bar (4-20ma, 2-wire 24VDC loop powered) Sample connection G½” mail thread Length approx. 135 mm Ex. Class II 1 G Ex ia IIC T6…T4 Ga

General pressure transmitter requirements:

Type 4-20mA, (2-wire 24VDC loop powered) Ingress Protection as for the particular application. Ambient Temp. -25 - +55 ºC Sample Temp. 0 - +65 ºC Measuring range 0-16 bar (any range 0-10 bar to 0-25 bar can be used) Sample connection G½” male thread Ex. Class must comply with the particular hazardous area


3.3. System Interfaces This section contains a list over electrical interfaces in the system with an electrical sample pump. More details about these signals’ setup can be found in chapter 7.8. Setup of parameters page 67 and about their connections in chapter 10.10. Electrical page 138.

Description Type Unit Subunit Terminal Mains, Computer unit 85-265VAC, 50/60Hz,

1-phase Computer Power unit 1, 2

Mains, Converting unit 440VAC, 60Hz, 3 phase/ 380VAC, 50Hz, 3 phase

Converting Power terminals 41-43

Communication, internal Modbus RTU, RS485 Computer/ Converting internal

Comp. I/O Conv. I/O Zener Barrier

17-19 21-23

Communication, internal Ex3, patented

Converting/ Analyzing/ internal Analyzing

Zener Barrier/ Connection box/ Measuring cell

ZMC 1, 2/ Header Socket

Communication, external (optional)

Modbus RTU, RS485 Computer Comp. I/O 44-46

Flow meter inputs ZF1 ZF2 CVF

Ex4, 4-20mA, active,24VDC Ex4, 4-20mA, active,24VDC 4-20mA, passive

Converting Converting Converting

Zener Barrier Zener Barrier Conv. I/O

ZF1 ZF2 CVF

Pressure transmitter input (internal)

Ex5, 4-20mA, active,24VDC Cable, preinstalled

Converting/ Analyzing/ Analyzing

Zener Barrier/ Connection box/ Pressure transm.

ZP 7, 8 2, 1

Overboard valve control EL1 EL2

Relay, potential free Relay, potential free

Computer Computer

Power unit Power unit

3, 4 5, 6

Manual override output Relay, potential free Computer Power unit 7, 8, 9 Alarm output Relay, potential free Computer Power unit 10,11,12 GPS receiver NMEA 0183, 4800 baud Computer Comp. I/O 21-23 VDR transmitter (optional) NMEA type, 4800 baud Computer Comp. I/O 41-43 Overboard valve position input EL1 EL1-INV (open indicate open) EL1-ZD1 EL2 EL2-INV (open indicate open) EL2-ZD2

12 VDC, 10mA 12 VDC, 10mA Ex6, 7 VDC, 10mA 12 VDC, 10mA 12 VDC, 10mA Ex6,7 VDC, 10mA

Computer Computer Converting Computer Computer Converting

Comp. I/O Comp. I/O Zener Barrier Comp. I/O Comp. I/O Zener Barrier

26, 27 26, 27 ZD1 28, 29 28, 29 ZD2

Speed log input 12 VDC, 10mA Computer Comp. I/O 30, 31 El. Sample pump control Contactor 440 VAC Converting Power terminals 44-46 Fresh water valve control Relay, 24 VAC Converting Conv. I/O 3, 4 Sample select control S1 S2

Relay, 24 VAC Relay, 24 VAC

Converting Converting

Conv. I/O Conv. I/O

5, 6 7, 8

Sample pump motor dis-connector switch feedback

12 VDC, 8mA Converting Conv. I/O 13, 14

Sample pump contactor feedback 12 VDC, 8mA Converting Conv. I/O 15, 16 High oil temp sample pump 12 VDC, 8mA Converting Conv. I/O 17, 18 Overcurrent input, internal 24 VAC Converting Conv. I/O 26, 27 Manual fresh water valve position input

Ex6, 7 VDC, 10mA Converting Zener Barrier ZD4

Unit and Subunit locations: item, cabinet Computer unit, Power unit: d1, CTB10001p sheet 3, Computer Unit with open door page 98 Computer unit, Comp. I/O d5 Converting unit, Power Terminals d3, CTB10003 sheet 3 of 4, Converting Unit page 102 Converting unit, Conv. I/O d5 Converting unit, Zener Barrier d6 Analyzing unit, Connection box d1, CTB10015 sheet 3 of 3, Analyzing unit skid with electrical Ex. motor sample pump page 106 Analyzing unit, Measuring cell d2 Analyzing unit, Pressure transmitter d4 3Interface for intrinsically safe communication between the Zener barrier and the Measuring cell. 4Interface for intrinsically safe flow meter only. 5Interface for intrinsically safe pressure transmitter only. 6Interface for intrinsically safe potential free contact.


4. Installation This chapter contains advice for the installation of CleanTrack 1000 B equipment on board tankers. The advice given in this chapter is of general validity and should be supplemented with a detailed installation specification for the particular ship. Additionally, all applicable regulations regarding the installation standard, issued by the relevant authorities and classification society must be followed. For instance, if CENELEC applies, compliance is required with EN 60079-14 and EN 60079-17.

4.1. Computer Unit 4.1.1. Mechanical Refer to drawings/chapters:

• CTB10030 sheet 1, chapter 10.1. Computer Unit page 97. Both wall and panel mount options are shown. • P3715090 sheet 1, Computer Unit panel mount instructions page 99.

The Computer Unit is installed in the cargo control room or an equivalent dry and non-hazardous area. 4.1.2. Electrical Refer to one of the drawings below:

• CTB110204.1el, chapter 10.10.1. Electrical cable diagram for electrical Ex. motor sample pump page 138. • CTB110204.1bh, chapter 10.10.2. Electrical cable diagram for bulkhead mounted sample pump page 139. • CTB110204.1pn, chapter 10.10.3. Electrical cable diagram for air motor sample pump page 140.

Supply voltage should be single phase 110/220VAC, 50-60Hz. (Computer unit work on voltages 85 - 265VAC). Power consumption 30VA. The power should be equipped with a main switch, or if specified, a detachable connector. The fuse size should be 6A. The alarm relay is normally open. An activated alarm is indicated with an open relay, which means that the alarm is activated when the power supply fails. Data communication between Computer Unit and Converting Unit, Cb5: Type: RS485 Baudrate: 19200 baud. Length: ≤1200 meters. (Might be shorter depending on cable used, see RS485 standards.)


4.2. Converting Unit 4.2.1. Mechanical Refer to drawing:

• CTB10003 sheet 1, chapter 10.2. Converting Unit page 100. The Converting Unit should be mounted vertically in a non-hazardous area, normally in the engine room, as close as possible to the Analyzing Unit at the other side of the bulkhead. The unit should be provided with enough space to open the cabinet door. 4.2.2. Electrical Refer to drawings:

• CTB10003 sheet 2 of 4, Converting Unit page.101. • CTB10003 sheet 3 of 4, Converting Unit page 102.

o Item d7 = equipotential rail, in the text below. o Item d8 = PE rail, in the text below.

For electrical explosion proof motor sample pump: • CTB10907 sheet 1 of 1, GA-plan with skid Ex. motor sample pump page 130. • CTB10917 sheet 1 of 1, GA-plan with skid Ex. motor sample pump and flushing page 131. • CTB10908 sheet 1of 1, GA plan with free standing Ex. Motor sample pump page 132. • CTB110204.1el, electrical cable diagram for electrical Ex. motor sample pump page 138.

For electrical bulkhead penetration sample pump: • CTB10906 sheet 1 of 1, GA-plan with bulkhead penetrating Sample pump page 133. • CTB10916 sheet 1 of 1, GA-plan with bulkhead penetrating Sample pump and flushing page 134. • CTB110204.1bh, electrical cable diagram for bulkhead mounted sample pump page 139.

For air motor sample pump: • CTB10901 sheet 1 of 1, GA-plan with air motor sample pump page 135. • CTB10911 sheet 1 of 1, GA-plan with air motor Sample pump and flushing page 136. • CTB10903 sheet 1 of 1, GA-plan with pilot-controlled air motor sample pump page 137. • CTB110204.1pn, electrical cable diagram for air motor sample pump page 140.

Refer also to the document “INSTRUCTIONS Oil Monitor interface type Z11”

• Chapter 4.9. Zener Barrier Instructions and Replacement page 25. The power supply should be equipped with a main switch, or if specified, a detachable connector. Fuse size should be 3 x 10A for Converting Units equipped to supply electrical motor sample pumps and a 6A fuse for air motor sample pumps. Check that the supply voltage corresponds to the voltage specified on the label below the mains terminals. A 3-pole disconnector switch can be installed in the safe area on Cb2 to being able to detach the sample pump while keeping power to the converting unit. This can be useful if a zener barrier input is used for the overboard valve feedback. An additional normally closed auxiliary contact can be monitored by the unit. Shields of cables for intrinsically safe equipment in both hazardous and non-hazardous area should normally be electrically connected to earth at one point only, normally in the non-hazardous area end of the circuit loop. This requirement is to avoid the possibility of the screen carrying a possibly incentive level of circulating current in the event that there are local differences in earth potential between one end of the circuit and the other. All shields of Cb7 and other cables for intrinsically safe equipment connected to the Zener Barrier PCB should be connected to earth. This is made via the equipotential rail (see CT10003 sheet 3 page 102, item d7) located below the Zener Barrier PCB at the right side in the Converting Unit. The rail is from factory connected to the PE rail (see CT10003 sheet 3 page 102, item d8) located at the low left side in the Converting Unit. The PE rail shall be connected to ground/earth (and the equipotential rail is then also connected to ground/earth). If another earthing system is preferred for the cable shields of the intrinsically safe equipment the equipotential rail should be disconnected from the PE rail and instead connected to the preferred earthing system. Connections must satisfy the requirements of the relevant classification society. Keep Cb7 and other cables connected to intrinsically safe circuits separated from non-intrinsically safe circuit cables. Data communication between Converting Unit and Analyzing Unit, Cb7: Baudrate: 19200 baud. Length: ≤50 meters.


4.3. Analyzing Unit 4.3.1. General drawings For item numbers and piping of a typical arrangement refer to drawing:

• CTB10601 sheet 1 of 1, Partnames of typical arrangement page 129. The Analyzing Unit/Measuring Cell should be mounted vertically and lower than the sample outlet probe, to safeguard a positive pressure in the sample water system at all times. For draining possibilities of the sample piping arrangement, the drain valve, item 42, should be the lowest point. A separate draining possibility for the pump head of the sample pump is needed for some pump types. 4.3.2. Mechanical For skid mounted electrical Ex. motor sample pump refer to drawings/chapters:

• Chapter 10.3.1. Analyzing Unit skid with Ex. motor Sample pump page 104. For free standing electrical Ex. motor sample pump refer to drawings/chapters:

• Chapter 10.4. SPP-100 Sample pump with Ex. Motor page 119. For electrical bulkhead penetration sample pump refer to drawings/chapters:

• Chapter 10.3.2. Analyzing Unit with external Sample pump page 107. • Chapter 10.5. Nikuni Sample pump for Bulkhead mounting page 121. • Chapter 10.6. Matre Sample pump for Bulkhead mounting page 124.

For air motor sample pump refer to drawings/chapters:

• Chapter 10.3.4. Analyzing Unit with Air motor Sample pump page 114. For retrofitting inside existing analyzing cabinet

• Chapter 10.3.3. Analyzing Unit with Freestanding items for External Sample pump page 112. • Chapter 10.7. Connection box page 126.

The Analyzing Unit should be mounted in the pump room with 4 bolts welded clips on the pump room to engine room bulkhead as close as possible to the Converting Unit at the other side of the bulkhead or in an equivalent suitable location. The unit should be provided with enough space to open the cabinet door and enough space to facilitate cleaning of the Measuring Cell from above with a brush. There should also be space for operating the valve handles and taking grab samples. The Analyzing Unit should be mounted lower than the sample outlet probe, to safeguard a positive pressure in the sample water system at all times. Any valves having coated aluminum levers should be protected from falling objects. 4.3.3. Electrical For skid mounted/free standing electrical Ex. motor sample pump refer to drawings/chapters:

• Chapter 12.8.1. Elprom instructions page 201 • CTB110204.1el, electrical cable diagram for electrical Ex. motor sample pump page 138 • Chapter 10.3.1. Analyzing Unit skid with Ex. motor Sample pump page 104. • Chapter 10.7. Connection box page 126

For electrical bulkhead penetration sample pump refer to drawings/chapters:

• CTB110204.1bh, electrical cable diagram for bulkhead mounted sample pump page 139. • Chapter 10.3.2. Analyzing Unit with external Sample pump page 107 • Chapter 10.7. Connection box page 126


• CTB110204.1pn, electrical cable diagram for air motor sample pump page 140. • CTB10010 sheet 3 of 5, Analyzing unit with air motor sample pump page 116. • CTB10010 sheet 5 of 5, Analyzing unit with air motor sample pump page 118. • Chapter 10.7. Connection box page 126


For retrofitting inside existing analyzing cabinet. Mount a freestanding measuring cell mounted with its hood and a connection box on the backplane. Refer to drawings/chapters: • Use cable diagram above for the actual sample pump used. • CTB10601 sheet 1 of 1, Partnames of typical arrangement page 129. • 10.3.3. Analyzing Unit with Freestanding items for External Sample pump page 112. • Chapter 10.7. Connection box page 126

Refer also to the document “INSTRUCTIONS Measuring cell type CTB11”

• Chapter 4.10. Measuring Cell Instructions and Replacement page 30 that also contains the drawings CTB10032, CTB10033 sheet 1 and CTB11036.

Check the Sample pump, the Measuring Cell and the Pressure transmitter documentation concerning intrinsically safety and that the equipment complies with the installation regulations for this particular hazardous area. Connect Cb7, Cb3 and Cb3a to the Connection box. Terminate the Cables according to the electrical cable diagram for the actual sample pump used. Shields of Cb7, Cb3 and Cb3a should all normally be connected to the equipotential rail in the Connection Box of the Analyzing Unit. The equipotential rail and shields are normally connected to earth in the nonhazardous area. Cables Cb3 and Cb3a can also be directly wired from the flow meter to the Converting Unit without connections via the Connection box. Make sure the Analyzing Unit and the Connection box is properly connected to earth according to the applicable regulations for this particular hazardous area. If an electrical Ex Sample pump is used: If a thinner cable, Cb2 is used than given in drawing CTB10015 sheet 2 of 3, Analyzing unit skid with electrical Ex. motor sample pump page 105 size down with a cable gland approved for the actual hazardous area and the pump temperature. Make sure the frame of the explosion proof motor is properly connected to earth according to the applicable regulations for this particular hazardous area. Refer to maker’s instruction chapter 12.8.1. Elprom instructions page 201 regarding connection of power supply and earth. 4.3.4. Inlet probe and Outlet stub For basic convention requirements, see Resolution MEPC.108(49) chapter 6.3. Refer to drawings in chapter 10.11. Sample probes page 143. The inlet probe is mounted upstream of the outlet stub and the flow meter sensor should preferably be mounted between the inlet probe and the outlet stub. A positive water pressure must be available in the discharge line under all discharge conditions at the place where the inlet probe is located. The outlet probe shall be located higher than the analyzing unit outlet connection. The sample feed pump may be damaged if run dry for more than 10 seconds. The sample valves and sample inlet filter should be located with adequate space and accessibility for servicing.


4.3.5. Piping of Sample Inlet and Outlet Pipes: Tb11 and Tb13 For skid mounted/free standing electrical Ex. motor sample pump refer to drawings/chapters:

• Chapter 10.9.2. GA-plan with Ex. motor Sample pump page 130. • Chapter 10.3.1. Analyzing Unit skid with Ex. motor Sample pump page 104. Recommended pipe dimensions for SPP-100 pump: Pipe diameter 15x1 mm Recommended maximum pipe length 10 m

According to response time calculations, maximum pipe length of Tb13 is 30 m. When using a long Tb13 pipe it is important to consider the pressure drop in Tb13, please see point 1.and 3. below in this chapter.

For electrical bulkhead penetration sample pump refer to drawings/chapters:

• Chapter 10.9.3. GA-plan with bulkhead penetrating Sample pump page 133. • Chapter 10.3.2. Analyzing Unit with external Sample pump page 107. • Chapter 10.5. Nikuni Sample pump for Bulkhead mounting page 121. • Chapter 10.6. Matre Sample pump for Bulkhead mounting page 124. Recommended pipe dimensions for Nikuni pump: Pipe diameter 22x1 mm Maximum pipe length 25 m (see points 1. and 3. below in this chapter)


• Chapter 10.9.4. GA-plan with Air motor Sample pump page 135. • Chapter 10.9.5. GA-plan with pilot-controlled Air motor Sample pump page 137. • Chapter 10.3.4. Analyzing Unit with Air motor Sample pump page 114. Recommended pipe dimensions for air motor pump: Pipe diameter 15x1 mm Maximum pipe length 12 m (see points 1. and 3. below in this chapter)

Other pipe dimensions than recommended above may be used but the 3 points below must be met at all time:

1. A positive pressure must be secured in Tb13 to avoid starvation of the sample pump. Relevant pressure drop calculations should be made.

2. The Drain Valve should be the lowest point of the inlet and outlet piping for efficient draining to avoid freezing damages.

3. The sample flow time should be recalculated to each installation to make sure that the requirements regarding total system response time is satisfied. See chapter 4.6. Response time calculations page 22.

The sample valves and sample inlet filter should be located with space for accessibility and servicing. 4.3.6. Piping for Fresh water (Option) Pipe: Tb8 For skid mounted electrical Ex. motor sample pump refer to drawing:

• CTB10917 sheet 1 of 1, GA-plan with skid Ex. motor sample pump and flushing page 131. For electrical bulkhead penetration sample pump refer to drawing:

• CTB10916 sheet 1 of 1, GA-plan with bulkhead penetrating Sample pump and flushing page 134. For air motor sample pump refer to drawing:

• CTB10911 sheet 1 of 1, GA-plan with air motor Sample pump and flushing page 136. The pipe should be provided with a shut of valve close to the bulkhead penetration. Bulkhead penetrations must satisfy the requirements of the relevant classification society. The fresh water supply should be provided with one shut off and one vacuum check valve and one check valve. The fresh water temperature should not be lower than the sample water temperature. Suitable temperature is about 0º - 10º Celsius warmer than the sample water temperature. The water should, however, not be warmer than 65º Celsius. The water consumption is about 200 to 600 l/h and is open about 45 seconds at start-up. It is also recommended to flush manually at closing down. This makes about 6-20 liters per start/stop.


The water pressure should not be higher than 5 bar and not less than 0.5 bar higher than the overboard line pressure at the sample outlet connection point. 4.3.7. Piping for Air motor (Air motor option only) Pipe: Tb20 Refer to drawings/chapters:

• CTB10601 sheet 1 of 1, Partnames of typical arrangement page 129. • 10.3.4. Analyzing Unit with Air motor Sample pump page 114.

The supplied air should be clean and dry. The pressure is displayed on a pressure gauge inside the Analyzing Unit. It is recommended to install a pressure regulator, a water trap and a filter. Air pressure at the pump 5.2 bar Air consumption, about 30 Nm³/h Note: Before first startup it is important that eventual residues from air pipe cutting and other activities are removed before the pipe is connected to the analyzing unit or the Speck air sample pump. These residues might harm the motor of the Speck air sample pump. Below table can be used as a guidance only for minimum pipe diameter for a given pipe length and a minimum initial pressure. The calculation is for a straight pipe, pressure drops at bends has not been taken in account. Make own calculations and have margin to allow the pressure regulator to work properly.

Pressure(final) = 5.2 bar (pipe inner diameter, [mm])

Pip

e len

gth

, [m

]

100 17 15 14 14 13 13 12 12 12 11 11 11 11 10 10 10 10 10

95 16 15 14 13 13 12 12 12 11 11 11 11 11 10 10 10 10 10

90 16 15 14 13 13 12 12 12 11 11 11 11 10 10 10 10 10 10

85 16 15 14 13 13 12 12 12 11 11 11 11 10 10 10 10 10 10

80 16 15 14 13 13 12 12 11 11 11 11 10 10 10 10 10 10 9

75 16 14 14 13 12 12 12 11 11 11 10 10 10 10 10 10 9 9

70 15 14 13 13 12 12 11 11 11 11 10 10 10 10 10 9 9 9

65 15 14 13 13 12 12 11 11 11 10 10 10 10 10 9 9 9 9

60 15 14 13 12 12 11 11 11 11 10 10 10 10 9 9 9 9 9

55 15 14 13 12 12 11 11 11 10 10 10 10 10 9 9 9 9 9

50 14 13 13 12 11 11 11 10 10 10 10 10 9 9 9 9 9 9

45 14 13 12 12 11 11 10 10 10 10 10 9 9 9 9 9 9 8

40 14 13 12 11 11 11 10 10 10 10 9 9 9 9 9 9 8 8

35 14 12 12 11 11 10 10 10 9 9 9 9 9 9 8 8 8 8

30 13 12 11 11 10 10 10 9 9 9 9 9 8 8 8 8 8 8

25 13 12 11 10 10 10 9 9 9 9 9 8 8 8 8 8 8 8

20 12 11 11 10 10 9 9 9 9 8 8 8 8 8 8 7 7 7

15 12 11 10 9 9 9 9 8 8 8 8 8 7 7 7 7 7 7

10 11 10 9 9 8 8 8 8 7 7 7 7 7 7 7 7 6 6

5 9 9 8 8 7 7 7 7 7 6 6 6 6 6 6 6 6 6

5.6 5.8 6.0 6.2 6.4 6.6 6.8 7.0 7.2 7.4 7.6 7.8 8.0 8.2 8.4 8.6 8.8 9.0

Initial pressure, [bar]


4.4. Flow meter and Speed log 4.4.1. Flow meter general “The monitoring system should comprise a flow rate indicating system to measure the rate of effluent being discharged into the sea.” Selection of flow meter type is optional. The flow meter should meet the following requirements according to IMO Resolution MEPC.108(49) chapter 6.4. “A flow meter for measuring the rate of discharge should be installed in a vertical section of a discharge line or in any other section of a discharge line as appropriate, so as to be always filled with the liquid being discharged. A flow meter should employ an operating principle suitable for shipboard use and, where relevant, which can be used in large diameters pipes. A flow meter should be suitable for the full range of flow rates that may be encountered during normal operation. Alternatively, arrangements such as the use of two flow meters of different ranges or a restriction of the operational flow rate range may be necessary in order to meet this requirement. The flow meter, as installed, should have an accuracy of ±10%, or better, of the instantaneous rate of discharge throughput the operating range for discharging the effluent. It might be necessary to limit the operational range of the discharge rate in order to achieve sufficient accuracy. The design of the flow meter arrangements should have regard to the safety requirements of the space in which such metering arrangements are located.” Any flow transmitter, having an output signal of 4-20mA and that complies with the regulations that applies to the particular installation may be used. Follow the instructions for the selected flow meter. Refer to chapter 7.8.2. ZF1 (Zener barrier flow input 1) page 68, ZF2 and CVF for software programming. 4.4.2. BRANNSTROM standard flow transmitter. Brannstrom Sweden has selected a flow transmitter that complies with the regulations and works well in the application. See drawings:

• CT891215.5, CleanTrack Flow meter unit, Vertical page 145. • CT900503.1, CleanTrack Flow meter unit, Horizontal page 146.

4.4.3. Speed log general “The monitoring system should comprise a ship speed indicating device to give the ship’s speed in knots.” The speed indication system should meet the following requirements according to IMO Resolution MEPC.108(49) chapter 6.5. “The automatic speed signal required for a monitoring system should be obtained from the ship’s speed indicating device7 by means of a repeater signal. The speed information used may be either speed over the ground or speed through the water, depending upon the speed measuring equipment installed on board.” Refer to chapter 7.8.7. Speed page 70 for software programming. The speed log signal connected to CleanTrack 1000 B should be a pulse signal from a voltage free relay or switch. The pulse frequency should be proportional to the speed. The data of the speed output signal should meet:

1. Minimum switch on or off time: 33 ms 2. Pulse frequency range: 45-250 pulses/nm.

7 See ”Recommendation on Performance Standards for Devices to Indicate Speed and Distance” (Annex to resolution A.824(19) as amended by resolution MSC.96(72)).


4.5. Paper Printer Item d2 drawing CTB10001p sheet 3, Computer Unit with open door page 98. An optional paper printer module containing a paper printer and a paper rewinder can be installed in the Computer Unit. The module is fastened with 4 screws on the right side of the computer unit. Electrically two cables from the printer and one from the rewinder is connected to the CUIO PCB at the bottom of the Computer Unit. Printer manage thermal roll paper with heat-sensitive side on outside of roll. Paper roll width: max 58 mm. Paper roll diameter: max 50 mm.

4.6. Response time calculations The overall response time should not be more than 40 seconds according to IMO Resolution MEPC.108(49) chapter 6.3.6. The “Overall response time” includes the “Response time of the installation” and the “Response time of the meter”. “Response time of the installation” is the time to transport the fluid from the overboard pipe to the Measuring Cell. (The time it takes to transport the fluid in the Sample inlet pipe.) “Response time of the meter” is the response time measured according to IMO Resolution MEPC.108(49) page 38. The response time of the installation may be calculated by using the formula below: (The example is for a sample pump with air driven motor.)

Response time of the sample piping = 𝐴∗ 𝐿∗60∗60

𝑄 [𝑠𝑒𝑐𝑜𝑛𝑑𝑠]

Where A = Cross sectional area of sample inlet pipe, [𝑚2] L = Length of sample inlet pipe from sample probe to Measuring Cell, [𝑚] Q = Flow rate of Sample Pump, [𝑚3/h] Response time of the oil content meter = 6.8 𝑠𝑒𝑐𝑜𝑛𝑑𝑠 Example:

A(15 mm pipe) = 𝜋𝑟2= 𝜋 ∗ (0.013

2)2 = 0.0001327 𝑚2

L = 10 𝑚 Q = 0.240 𝑚3/h

Response time of the sample piping = 0.0001327 ∗ 10 ∗ 60 ∗ 60

0.240 = 19.9 𝑠𝑒𝑐𝑜𝑛𝑑𝑠

Overall response time = 19.9 + 6.8 = 26.7 𝑠𝑒𝑐𝑜𝑛𝑑𝑠 (maximum 40 seconds allowed) Nominal flow of some sample pumps: Sample pump with Ex motor (SPP-100) 600 l/h Bulk head mounted (Nikuni or Matre): 900 l/h Sample pump with air driven motor: 240 l/h


4.7. First Start up Checklist Very important that all electrical wires are properly tightened. A wire that falls on secondary side of the zener barriers or on an explosion proof electrical sample pump connection might cause serious damage. Reference should also be made to chapter 6. Menu operations page 41 and chapter 7. Menu layout page 45.

1. Check that the supply voltage, to be connected to the Converting Unit (Cb1) corresponds to the voltage mark, normally placed on lower left side inside the unit.

2. Check that all Zener Barriers are connected correctly (Cb7, Cb3 and optionally Cb3a). Verify that the intrinsically safe arrangements are in order for the cables. See chapter 4.11. Calculations on intrinsically safe arrangements page 36.

3. Check the Sample Pump connection (Cb2 or Cb4), communication to Computer Unit (Cb5) and eventual other connections to the Converting Unit PCB. If an explosion proof electrical sample pump is used:

o check the motor frame to be connected to earth and that a correct cable gland is used and tightened. If an electrical motor bulkhead sample pump is used:

o check and/or refill oil in pump shaft seal. See chapter 9.7. Sample Pump Shaft seal oil refilling page 93.

If an air motor sample pump is used: o it is important that eventual residues from work with the air pipe and other activities are removed

from the piping before the pipe is connected to the analyzing unit or the Speck air sample pump. These residues might harm the motor of the Speck air sample pump.

o drain the water trap and adjust the pressure regulator until the pressure gauge in the Analyzing Unit cabinet shows 5.2 bar. See drawing: CTB10010 sheet 5 of 5, Analyzing unit with air motor sample pump page 118, item d6.

4. If an electric sample pump is used, check the setting of the overcurrent relay to correspond to the current of the electrical sample pump motor. See item d1 of drawing: CTB10003 sheet 3 of 4, Converting Unit page 102.

5. Connect mains to the converting unit and check that at least one light emitting diode on top right of both PCB’s in the unit are lit or flashing.

6. Check that the supply voltage to be connected to the Computer Unit (Cb8b) corresponds to the voltage mark, normally placed on the lower left side inside the unit.

7. On the Computer unit also check connections for valve(s) (Cb8a) and feedback(s) (Cb13), for communication to Converting Unit (Cb5), GPS input (Cb29) and Log input (Cb12) if speed log is used.

8. Connect mains to the computer unit. After a few seconds 2 different “Brannstrom Sweden” will appear on the screen before the screen goes black again and about 2 minutes later the Cleantrack1000B software appears.

9. The following should be set up or checked at the Computer Unit, refer to chapter 7.8. Setup of parameters page 67. • Sample pump selected. • Flushing water configuration. • Manual override settings. • Converting unit type setting. • Valve control and feedback. • Pressure transmitter programming and limits. • Flow meter programming and limits. • Speed log programming and limits. • GPS input. • Printer option.

Check chapter 7.3. Alarm Table page 53 for alarms and consult chapter 8. Fault-finding page 82 for fault finding. Communication is continuously going on between the Computer Unit, the Converting Unit and the Measuring Cell. This gives that all communications must be in working order, if not communication alarms are generated. If an air motor sample pump is used a second adjustment of the pressure regulator should be made while the sample pump is running. Setting the pressure gauge in the Analyzing Unit cabinet to 5.2 bar while the sample pump is running will also compensate for the pressure drop in the air pipe to the Analyzing Unit. It should be checked that a running sample pump stops and activate a "40 Alarm - High Work Pressure" if a valve on the sample outlet line is closed. It should be checked that a running sample pump stops and activate a "41 Alarm - Low Work Pressure" if a valve on the sample inlet line is closed. To make suitable settings, see chapter 4.8. Pressure alarm settings page 24 and chapter 7.8.5. Pressure page 69. The pressure alarms above are important to avoid to harm the Sample Pump unit, by pumping towards a closed valve (blockage) or pumping when dry (starvation). The pressure alarms are also important to detect a “loss of sample”. After finishing the first start-up it is recommended to save settings on a USB-stick. See chapter 7.5. USB page 56.


4.8. Pressure alarm settings The pressure alarms are important to avoid to harm the Sample Pump unit, by pumping towards a closed valve or pumping when dry. The pressure alarms are also important to detect a “loss of sample”. The calculations below show how to set these limits. It should be checked that a running sample pump stops and activate a "40 Alarm - High Work Pressure" if a valve on the sample outlet line is closed. It should be checked that a running sample pump stops and activate a "41 Alarm - Low Work Pressure" if a valve on the sample inlet line is closed.

1. Make the CleanTrack ready for “RUNNING” mode, see chapter 5.2. Start-up procedure page 38 but without starting discharge. Ensure there is water in the overboard line, the sample inlet line and the sample pump so that the sample pump not is running dry.

2. Work with the “Operate”/“Running” menu, see chapter 7.2.1. Running page 46. Calculated pressure limits are inserted in the “Setup”/”Pressure”-page, see chapter 7.8.5. Pressure page 69.

3. In the “Status”-page select “Disable Pressure check”, giving a flashing red indication at the right side. 4. With Sample Pump not running, read the Static Pressure from the overboard line,

Pstatic = _______ bar (1). 0.5 bar (example values for (1) to (8)) 5. Start the Sample Pump, read the Working Pressure,

Pwork+Pstatic = _______ bar (2). 3.7 bar 6. While the Sample Pump is running close a valve on the sample outlet, read the Closed Pressure,

Pclose+Pstatic = _______ bar (3). 5.1 bar 7. Subtract the static pressure to get work and close pressure:

Pwork = (2) – (1) = _______ bar (4). 3.2 bar Pclose = (3) – (1) = _______ bar (5). 4.6 bar

8. Calculate the pressure increase when pumping against a closed valve, Pcloseinc = (5) – (4) = _______ bar (6). 1.4 bar

9. High limit alarm should normally be set to work pressure multiplied by 0.4 the pressure increase, Pworkhigh = (4) + 0.4 * (6) = _______ bar (7). 3.8 bar Set “Sample High limit” to this value, see chapter 7.8.5. Pressure page 69

10. Low limit alarm should normally be set to work pressure multiplied by 0.75. Pworklow = 0.75 * (4) = _______ bar (8). 2.4 bar Set “Sample Low limit” to this value, see chapter 7.8.5. Pressure page 69

11. In “Status”-page select the earlier selected “Disable Pressure check”, and the flashing red indication on the right side of the screen will disappear.

12. If the unit has automatic flushing, the same procedure can be repeated but with opening the Water Valve instead of starting the Sample Pump. The values to set is “Water High limit” and “Water Low limit”, they are set on the same page as the Sample limits are. These values might have to be changed when the pressure in the overboard pipe increases. The limits for fresh water are however not essential the same way as the sample limits are.

13. When finished following the relevant steps in the 5.3. Close down procedure page 39.

Start Sample Pump here.

Open Water Valve here.

In “Status”-page, press: “Disable Pressure check”.

Read Pressure

here.


4.9. Zener Barrier Instructions and Replacement






4.10. Measuring Cell Instructions and Replacement




4.10.1. Measuring Cell replacement (CTB10032)


Drawing: CTB10033 sheet 1, Measuring Cell assembly and connection.


Drawing: CTB10036 sheet 1, Measuring Cell console hole pattern.


4.11. Calculations on intrinsically safe arrangements This chapter is a guidance, and nothing but a guidance, on how to demonstrate the intrinsically safety margins of the installation. The installation engineer, and no one but the installation engineer, is responsible for the intrinsically safety of the installation. No responsibility is given for the data below. Correct data is printed on the actual included apparatus or its certificate. The Zener barriers, ZBs, in the Converting Unit are arranged in order to supply 5 separate intrinsically safe circuits, ISC. The following data applies to zone IIC.

Table of entity parameters Parameter Circuit F2 Circuit F1 Circuit P Circuit D Circuit MC Co 90nF/80nF 90nF/80nF 90nF/80nF 2.5μF 2.5μF Lo 3mH/1.4mH 3mH/1.4mH 3mH/1.4mH 3mH 0.9mH Uo 26V 26V 26V 8.41V 8.41V Io 81mA 81mA 81mA 59.6mA 193.1mA Po 0.53W 0.53W 0.53W 0.187W 0.41W

ISF2/F1 Intrinsically safe Flow meter.

• Values below from Fuji flow meter, type FCX-AIII or FCX-AII. See chapter 12.7. Flow meter, Fuji page 198. ISP Intrinsically safe Pressure transmitter.

• Values below from Siemens type /MF156x. ISD Intrinsically safe mechanical switch.

• Values below from an unspecified type. ISMC Intrinsically safe Measuring Cell

• Values below from Measuring Cell type CTB11. Note: The values for ISF2/F1, ISP and ISD depends on the actual apparatus.

Parameter ISF2 ISF1 ISP ISD ISMC Ci 26nF 26nF 0nF 0nF 2μF Li 0.6mH 0.6mH 0mH 0mH 0.165mH Ui 28V 28V 30V 28V 8.41V Ii 94.3mA 94.3mA 100mA 100mA 193.1mA Pi 0.66W 0.66W 0.750W ---- 0.41W

Any apparatus should relate to the supplying zener barrier circuit in the following way: Pi ≥ Po Ui ≥ Uo Ii ≥ Io Co – Ci = Cm Lo – Li = Lm Below follows Cm and Lm margins based on the circuit and apparatus data below:

Parameter Circuit F2/ISF2 Circuit F1/ISF1 Circuit P/ISP Circuit D/ISD CircuitMC/ISMC Cm 54nF 54nF 80nF 2.5μF 0.5μF Lm 0.8mH 0.8mH 1.4mH 3mH 0,735mH Ccable 200pF/m 200pF/m 200pF/m 200pF/m 200pF/m Lcable 1μH/m 1μH/m 1μH/m 1μH/m 1μH/m

The Ccable and Lcable are typical values given in EN_60079-14, calculation for the actual cable in use shall be made. Maximum cable length for Circuit F/ISF is 270m.

• If wiring is both in cable Cb3 and Cb7, values for actual length in both cables must be added. Maximum cable length for Circuit P/ISP is 400m. Maximum cable length for Circuit D/ISD is 3000m. Maximum cable length for Circuit MC/ISMC is 735m.

• The maximum tested length of this cable, Cb7, is 100m. Also check the temperature class of installed intrinsically safe apparatus and if the specified zone is acceptable. Concerning cables to intrinsically safe equipment the writing in the standard, IEC 60079-14, is:


“12.2.2.2 Electrical parameters of cables The electrical parameters (Cc and Lc) or (Cc and Lc/Rc) for all cables used (see 12.2.5) shall be determined according to a), b) or c): a) the most onerous electrical parameters provided by the cable manufacturer; b) electrical parameters determined by measurement of a sample; NOTE Annex C details a satisfactory method of determining the relevant parameters. c) 200 pF/m and either 1 μH/m or 30 μH/Ω where the interconnection comprises two or three cores of a conventionally constructed cable (with or without screen).”


5. Start/Stop procedure

5.1. General information before Start-up

• Use protective googles and follow normal occupational safety on a ship. • Prevent the sample pump from running dry or against a closed valve. • The overboard line must be filled with water. • Pressure settings correct according to chapter 4.8. Pressure alarm settings page 24.

5.2. Start-up procedure

1. Check the sample pump If the sample pump is powered by an electrical Ex. proof motor:

• Check mounting and cable penetrations of motor to be tightened and in order. • Check pump connections and fittings to be tightened and in order.

If the sample pump is bulkhead mounted: • Check Sample Pump Shaft seal oil level.

See chapter 9.7. Sample Pump Shaft seal oil refilling page 93. 2. Inspect and clean the Inlet Sample Filter, pos 15. See chapter 9.6. Cleaning of Inlet Filter

page 93. 3. Check that the Measuring Cell is mounted in its Analyzing unit docking position.

(It might have been removed for cleaning or service). 4. Remove the Measuring Cell Cleaning Cap and brush the Measuring Cell pipe with the cell

brush dipped in cleaning solution. 5. Check that the Flow Meter capillary Valves, pos VF1 and VF2 above are open. 6. Check that the Drain Valve and the Grab Sample Valve, pos 42 and 43 are closed. 7. Open all valves of the inlet pipe, pos 19a, 19b and 40. 8. Open the Grab Sample Valve, pos 43 slightly and bleed out any air until the inlet pipe Tb13,

the Sample Pump and the Measuring Cell are filled with water from the overboard line. 9. Close the Grab Sample Valve, pos 43. 10. Check for leakages around the Measuring Cell and inside the Analyzing unit. 11. Open all valves of the outlet pipe, pos 40, 18b and 18c. 12. If automatic Fresh Water flushing is installed, check that Fresh Water Valves, pos 31, 35

and 37 are open. 13. Prepare the Converting unit/Sample pump.

If the sample pump is powered by an electrical motor: • Check that power is connected to the Converting unit. • If installed, check that the sample pump disconnector switch is ON.

If the sample pump is powered by an air motor:


• Check that the air motor Exhaust protection (muffler) is not clogged, see drawing CTB10010 sheet 4 of 5, Analyzing unit with air motor sample pump page 117.

• Check that the valve between the Analyzing Unit and the Exhaust protection (if installed) is open.

• Drain the air supply water trap and check that all air supply valves are open. Check that the air pressure is 5.2 bar (on the Analyzing Unit air motor pressure gauge) when the Sample Pump is running.

14. Check that there are no alarms on the Computer unit, and if necessary, reset the alarms. 15. Select "Discharge line", "Oil type" and check that "Total Quantity of Oil Discharge" is set to

1/30000 of previous cargo. Note that the "Total Quantity of Oil Discharge" should be reset only when starting a new cargo voyage (See MARPOL Annex I regulations). See chapter 7.2.2. Running Settings, page 47.

16. Press the "Start Discharge" key on the Computer Unit’s "Operate" page and confirm start on the next popup window.

17. If automatic Fresh Water Control is installed: A flushing procedure of about 45 seconds can be selected first.

5.3. Close down procedure

1. Press the "Stop Discharge" key on the Computer Unit’s "Operate" page and confirm stop on the next popup window.

2. If automatic Fresh Water flushing is installed, flush the Analyzing unit manually via the Computer unit menu.

3. Check that the overboard valve is closed. 4. Check that the sample pump has stopped.

If the sample pump is powered by an electrical motor: • Check that the motor fan is not moving.

If the Sample pump is powered by an air motor: • Check that no air flows out of the Exhaust protection (muffler)

5. If automatic Fresh Water flushing is not installed and the piping & analyzing unit has been contaminated, manually flush the Analyzing unit and the piping to the overboard pipe using a temporary flushing hose.

6. Close inlet and outlet valves, pos 19a, 19b, 18b and 18c. 7. Close down Converting unit/Sample pump

For a sample pump powered by an electrical motor: a. If installed, set the sample pump disconnector switch to OFF. b. For units with serial numbers lower than CTB 2892, check that the sample pump

contactor feedback is enabled. See chapter 7.8.9. System Configuration, Alarms&Extras page 71 and the setting of the property “ConvertingUnitType” is “PumpFeedback”.

For a Sample pump powered by an air motor: c. Close all air supply valves. d. Close the valve between the Analyzing Unit and the Exhaust protection, if installed.

8. If automatic Fresh Water is installed, close Fresh Water Valves, pos 31 and 35. 9. Close Flow Meter capillary Valves, pos VF1 and VF2.

5.4. Closing down for a longer time or preserving for sub-zero conditions

10. Check that steps in the 5.3. Close down procedure above has been followed. 11. Check that flow Meter capillary Valves, pos VF1 and VF2 are closed. Bleed any water from

the capillary pipes and the differential pressure transmitter. Carefully blow dry with air, make sure not to exceed the pressure ratings. For more details, see the DP transmitter maker’s instructions.


12. Open the Drain and Grab Sample Valves, pos 42 and 43 and use pressurized air to blow out any water from the piping. Drain the sample pump and blow out any remaining water with air. Drain any part of the fresh water piping (if installed) which could be subjected to sub-zero temperatures.

13. The measuring cell can be disconnected and removed. If so, clean it, and store it in a dark, dry and temperature controlled location.


6. Menu operations

6.1. Main Menu and Top of Page indications Important information is show on top of all menus, see below. Running information:

• Grey “Stand By” “No discharge going on, unit is not started. This is called the “StandBy” mode.

• Yellow “RUNNING” Unit is started for discharge. The overboard valve is opened if the oil discharge rate is below 30 L/nm. This mode is called the “RUNNING” mode

• Yellow/Black “RUNNING” Flushing at start-up or closing down. Overboard valve information:

Note that the valve indication has to be fixed for a few seconds before the new position is recorded in “Recorded data”. This is to avoid printouts generated by glitches.) • Grey “Valve Closed” Overboard valve is closed. • Grey/Black “Valve Closed” Overboard valve is closed but the output control is opening the valve. • Yellow “VALVE OPEN” Overboard valve is open. • Yellow/Black “VALVE OPEN” Overboard valve is open but the output control is closing the valve.

Manual Override information • Grey “Auto” Oil Concentration, Overboard valve control, flow, speed and position

inputs are all in automatic mode. • Red “Manual Override” One or several of the above selections are in manual mode. Alarm status:

• Grey “Alarm” No alarms are active. • Red “ALARM” Active alarms that has been reset. • Red/Black “ALARM” At least one active alarm that has not been reset.

Date and Time

Running mode indication “StandBy” or “RUNNING”.

“StandBy, ##V” indicate voltage for optional heater.

Overboard valve indication.

Manual override indication.

Alarm status.

Set LCD background light intensity. A press to the left gives a darker display and to the right a brighter display.

Submenu select keys, described below.


6.2. Edit Numeric values Values with white background are set values and can be changed. Press the indicated value with the tip on your finger and a Numeric Keyboard pops up. Normally the present value and text to indicate the selection are displayed on the Numeric Keyboard.

This example shows the "Speed High limit" being set to 20.0 kn. After the value has been entered, save with the "Ok" key or cancel change with "Cancel" key.

6.3. Keys All keys, if not greyed out, can be pressed. The function of a key is explained by text above or in the key. Different actions and feedback are taken by the computer depending on which key is being pressed. The key can change the displayed menu, open a submenu, open a drop-down list or simply change color to yellow as an indication of activation. An example of a submenu is this verification menu which opens when the "Manual Override Discharge Valve" key is pressed:


6.4. Password Some operations need a "Password" and when pressed they opens up a "Password submenu"

First enter the Password and then select "Admin" for administrator level or "User" for lower level. The most commonly used passwords are the ones needed to enter sub menus from the “Main Menu”

• “Setup” – Password “3” and “Admin” • “Computer” – Password “1” and “User” • “System check” – Password “2” and “Admin”


6.5. Measuring Cell - Indications and Keys Front of Measuring Cell.

The front of the "Measuring Cell" has two yellow light emitting diodes, "D1" and "D2". It also has 2 touch keys, "KA" and "KB". The yellow light emitting diodes, D1 and D2, normally indicates if ODME is in "StandBy"-mode, "RUNNING"-mode or "RUNNING STARTUP"-mode. In ”RUNNING STARTUP"-mode or during "CALIBRATION" they can also indicate that the ODME is waiting for a key input. This key input can be given on the touch panel of the "Computer Unit" or on keys "KA" or "KB" on the "Measuring Cell" front. D1 and D2 Flashing SINGLE - Indicating discharge in "StandBy" -mode and no Water in Measuring Cell.

"Flashing LEFT" - Indicating discharge in "StandBy"-mode and Water in Measuring Cell ON OFF ONOFF

MC-D1 MC-D2

"Flashing RIGHT" - Indicating discharge in "RUNNING"-mode ON OFF ONOFF

MC-D1 MC-D2

"D1 Flashing SINGLE, D2 Flashing DOUBLE" - Waiting for KB to be pressed ON OFF ONOFF

MC-D1 MC-D2

"D1 Flashing DOUBLE, D2 Flashing SINGLE" - Waiting for KA to be pressed ON OFF ONOFF

MC-D1 MC-D2

0s 1s 2s

0s 1s 2s

0s 1s 2s

0s 1s 2s


7. Menu layout

7.1. Main Menu See chapter 6. Menu operations page 41 for top of page information and key usage. This menu can be reached by selecting the key “Main Menu” on the bottom right of every submenu or by selecting “Continue” on the “Start page”.

"Operation" Go to "Operation" page. Chapter 7.2. Operation, page 46 "Alarm" Go to "Alarm table". Chapter 7.3. Alarm Table, page 53 "Recorded data" Go to "Recorded data table". Chapter 7.4. Recorded data, page 54 "USB" Go to "USB" page. Chapter 7.5. USB, page 56 "On board test" Go to "On board test" page. Chapter 7.6. On-board Test, page 59 "Calibration" Go to "Calibration" page. Chapter 7.7. Measuring Cell Check/Calibration page 63 "Setup" Go to "Setup" page. Chapter 7.8. Setup of parameters, page 67 Password: "3" and "Admin". "Computer" Go to "Computer" page. Chapter 7.9. Computer, page 73 Password: "1" and "User". "System check" Go to "System check" page. Chapter 7.10. System Check, page 75 Password: "2" and "Admin". "Approvals" Go to "Approvals" page. Chapter 7.11. Approvals page 81 7.1.1. Start page If the touch screen is inactive for more than about 30 minutes the “Start page” will be shown. Select “Continue” to go to the “Main Menu”.


7.2. Operation 7.2.1. Running All important information during “RUNNING” mode of the system is displayed. Use “Running Settings” for all settings before a discharge. The piping arrangement turns blue or grey depending on input / output signal status.

• Overboard valve is grey, indicating closed, and slop tank valve is blue, indicating open. • The water sensor in the measuring cell is not active and this is displayed with grey sample lines. The sample

lines turn blue when the water sensor is activated. • The "Sample pump" turn blue when its control output is on. • The “Water”-valve turn blue when its control output is on. • The Overboard line turns blue when the measured discharge flow is within the flow limits. • Indications counting down seconds can be displayed, indicating that the unit is waiting for an event. These

indications are for information only and can be ignored, alarms are generated for failures.

"Oil type" Indicates the selected “Oil type”. Select in the “Running Settings”-menu. "Discharge Line" Indicates the selected “Discharge Line” Select in the “Running Settings”-menu. "START Discharge" Starts the unit for discharging of the water.

Refer to Chapter 5. Start/Stop procedure page 38 before starting discharge. When the unit goes into “RUNNING” mode, the key which previously was called "START Discharge" will now display the text "STOP Discharge". A submenu is displayed asking for START verification, or if any input signal or other selection prohibits the START, the "Status” menu indicating the reason will be shown.

"Alarm Reset" A RED “Alarm Reset”- key pops up above the “Main Menu” key. It there are any active alarms which have not been acknowledged, the “Alarm” indication on top right is flashing. Same function as the "Reset" key in the "Alarm table".

“Enable test of: Pump & Water” Enables manual running of the Sample Pump and opening of the Water Valve. This selection needs to be verified on a popup window. The two keys below will be shown after the “Enable test ...” key has been pressed. Refer to Chapter 5. Start/Stop procedure page 38 before activation of pump or water.

"Pump 60 sec" Manually run the sample pump for 60 seconds, useful for testing. Pressure check and Water check is enabled and may prohibit start of the pump. Further described in chapter 7.2.4. Status page 52 below.

"Water 60 sec" Manually flush with fresh water for 60 seconds (if automatic flushing has been installed), useful for testing.

“Man. Close” Option for “Valve control” settings “EL1/EL2” and “EL1/EL2-n”. Activate relay output for closing of slop tank valve. Refer to chapter 7.8.1. Line of discharge page 67.

“Conv. Unit” Option for an “Extended” converting unit. A table showing sample pump motor data. “Show Motor” Option for an “Extended” converting unit. Showing the “Conv. Unit” table above.

Only for Extended Converting unit

Only for Valve Control: EL1/EL2 or EL1/EL2-n

Indicating “opening” or “closing” while discharge output and feedback indicated on valves do not correspond.


7.2.2. Running Settings Selection and settings to be made before start discharging after a voyage.

"Discharge line" Select line for discharging. A popup menu will be displayed for selection. "Oil type" Select oil type. A submenu will be displayed for selection. "Max. oil discharge" Set to 1/30 000 of the total quantity of the particular cargo of which formed a part. "Clear Total oil discharge" Reset the accumulated value when all tank washing residues have been discharged

and a new cargo will be loaded. "Total. oil discharge" Accumulated total oil. The discharge is disabled (valve output deactivated) when

the value exceeds the “Max. oil discharge” value. The value is accumulated when the unit is in “RUNNING” mode and:

1. Discharge is enabled (valve output activated), or; 2. Valve feedback is active, or; 3. “Manual Override Overboard Valve” is enabled.

7.2.2.1. "Discharge line" Discharge line popup menu. (This popup menu will differ depending on selections made in Chapter 7.8.1. Line of discharge page 67)

"#1", "#2", "#3" or “#4” Select line for discharging.


7.2.2.2. "Oil type" Oil type popup menu with bio-fuel blends.

Oil type popup menu with bio-fuel blend types in accordance with MEPC.1/Circ.761 and MEPC.240(65). Please, refer to chapter 7.11. Approvals page 81 regarding upgrading for more bio-fuel blends.

Oil types "No.1 Crude Oil" - "No.6 Crude Oil" are according to "No 1-6 crude oils" in MEPC.108(49). Oil types “Automotive Gasoline”, “Kerosene” and “Mar.Dist FO – DMA” are according to "White petroleum products" in MEPC.108(49). The bio-fuel blended types are in accordance with MEPC.1/Circ.761 and MEPC.240(65) and Annex 11 of MEPC.2/Circ.23.


No 1-6 crude oil and white petroleum products MEPC.108(49) as amended Oil Type Density Viscosity Pour Point General description

No.1 Crude Oil Low Medium Very low Mixed base No.2 Crude Oil Medium Medium Low Mixed base No.3 Crude Oil High Medium Low Naphthenic No.4 Crude Oil Very high Very high Low Asphaltic No.5 Crude Oil Medium High Very high Paraffinic

No.6 Crude Oil Marine residual fuel oil - RMG 35. RMG 35 Parameters as per ISO 8217:2010/Corr 1:2011 (tables 1 and 2.)

Automotive Gasoline Automotive Gasoline Kerosene Kerosene

Mar.Dist. FO - DMA Marine distillate fuel oil - DMA – ISO 8217:2010/Corr 1:2011 (tables1 and 2)

Bio-fuel blends MEPC.1/Circ.761 and MEPC.240(65) and Annex 11 of MEPC.2/Circ.23 as revised

Blended Type Description

1%-15% FAME Bio-fuel blends of Diesel/gas oil and FAME (>85% but <99% Diesel gas oil by volume)

10%-25% FAME Bio-fuel blends of Diesel/gas oil and FAME (>75% but <90% Diesel/gas oil by volume)

1%-15% Veg.Oils Bio-fuel blends of Diesel/gas oil and Vegetable oils (>85% but <99% Diesel/gas oil by volume)

10%-25% Veg.Oils Bio-fuel blends of Diesel/gas oil and Vegetable oils (>75% but <90% Diesel/gas oil by volume)

1%-15% Ethyl alcohol Bio-fuel blends of Gasoline and Ethyl alcohol (>85% but <99% Gasoline by volume)

10%-25% Ethyl alcohol Bio-fuel blends of Gasoline and Ethyl alcohol (>75% but <90% Gasoline by volume)

1%-15% Alkanes C10-C26,fp>60°C

Bio-fuel blends of Diesel/gas oil and Alkanes (C10-C26), linear and branched with a flashpoint >60°C (>85% but <99% Diesel/gas oil by volume)

10%-25% Alkanes C10-C26,fp>60°C

Bio-fuel blends of Diesel/gas oil and Alkanes (C10-C26), linear and branched with a flashpoint >60°C (>75% but <90% Diesel/gas oil by volume)

1%-15% Alkanes C10-C26,fp<=60°C

Bio-fuel blends of Diesel/gas oil and Alkanes (C10-C26), linear and branched with a flashpoint ≤60°C (>85% but <99% Diesel/gas oil by volume)

10%-25% Alkanes C10-C26,fp<=60°C

Bio-fuel blends of Diesel/gas oil and Alkanes (C10-C26), linear and branched with a flashpoint ≤60°C (>75% but <90% Diesel/gas oil by volume)

1%-25% Alkanes C4-C12

Bio-fuel blends of Naphtha and Alkanes (C4-C12), linear, branched and cyclic (>75% but <99% Naphtha by volume)


Bio-fuel blends of Naphtha and Alkanes (C5-C7), linear and branched (>75% but <99% Naphtha by volume)

1%-25% Alkanes C9-C24,fp>60°C

Bio-fuel blends of Diesel/gas oil and Alkanes (C9-C24), linear, branched and cyclic with a flashpoint >60°C (>75% but <99% Diesel/gas oil by volume)


Bio-fuel blends of Kerosene and Alkanes (C10-C17), linear and branched (>75% but <99% Kerosene by volume)

1%-25% Alkanes Tert-Amyl ethyl ether

Bio-fuel blends of Naphtha and Tert-Amyl ethyl ether (>75% but <99% Naphtha by volume)


The table below together with the 2 tables above should be used as a guidance for selection of oil type setting for oils of various kinds.

Oil origin or type Oil type setting Sahara Blend No.1 Crude Oil Arabian Light crude No.2 Crude Oil Nigerian Medium crude No.3 Crude Oil Bachaquero 17 crude No.4 Crude Oil Minas crude No.5 Crude Oil Bunker C No.6 Crude Oil Automotive Gasoline Automotive Gasoline Kerosene Kerosene Diesel Oil Mar.Dist FO - DMA Ekofisk No.2 Crude Oil DUC No.2 Crude Oil Statfjord No.5 Crude Oil Brent No.5 Crude Oil Light Arabian Gulf crude's No.2 Crude Oil Light North Africa and West Africa crude's No.2 Crude Oil Light USSR crude's No.2 Crude Oil Marine diesel and light fuel oil Mar.Dist FO - DMA Heavy Arabian Gulf crude's No.3 Crude Oil High paraffin content crude's No.5 Crude Oil Mixed slop No.3 Crude Oil Asphalt crude's No.4 Crude Oil Lubrication oil No.4 Crude Oil Heavy fuel oil No.6 Crude Oil Kerosene and JP1 jet fuel Kerosene Gasoline and JP4 type jet fuel Automotive Gasoline


7.2.3. Manual Override This page allows you to insert and use manual values in case of equipment malfunction. The “Manual Override” indication will turn red if any manual is selected. Note that manual selections are recorded in “Recorded data”, and PSC will demand an acceptable reason for it. “Manual Oil conc”, “Manual Flow”, “Manual Speed” and “Manual Position” will automatically return to automatic mode 30 minutes after last activation or after return from “RUNNING” mode to “StandBy” mode.

"Manual Override Forcing the Overboard Valve to open. Overboard Valve" This selection needs to be verified on a popup window. For setting of relay output function see chapter: 7.8.8. System Configuration, Standard page 71. "Oil conc." Press value indication to insert manual value. "Manual Oil conc.” (Text in key during “StandBy” mode)

"Override Oil concentration with the value inserted in "Oil conc." This selection needs to be verified on a popup window. Communication and readings from the Measuring cell and the Pressure transmitter are ignored. The sample pump is not started. A “Warning” with activated Alarm relay and Buzzer is raised every 10-20 minutes to alert a user that this manual is active.

"Manual Oil conc. Running” (Text in key during “Running” mode) "Override Oil concentration with the value inserted in "Oil conc." This selection needs to be verified on a popup window. Communication and readings from the Measuring cell and the Pressure transmitter are checked as if this selection was not activated. This selection was made during running mode and will automatically be deselected when the running mode ends.

"Flow" Press value indication to insert manual value. "Manual Flow" Override discharge Flow with the value inserted in "Flow"

This selection needs to be verified on a popup window. Flow alarms are no longer generated with this selection active. If both “Manual Oil conc.” and “Manual Flow” are activated and neither “ZD1” nor “ZD2” are used for Overboard valve feedback, no communication with the Converting unit is needed and the Computer unit works as a “stand-alone” unit.

"Speed" Press value indication to insert manual value. "Manual Speed" Override ship's speed with the value inserted in "Speed"

This selection needs to be verified on a popup window. “Auto GPS” Indicating actual position or an error message. “Manual GPS” Press indicator to manually insert coordinates for the shop’s position. "Manual Position" Override ship's position with the "Manual GPS" value.

This selection needs to be verified on a popup window. “Timeout of any 4 manuals” Display of the 1800 seconds (30 minutes) countdown timer that which

automatically resets all of the 4 manual selections “Manual Oil conc”, “Manual Flow”, “Manual Speed” and “Manual Position” to automatic mode again.

Text in key is changed from “Manual Oil conc.” to “Manual Oil conc. Running” during ”Running” mode


7.2.4. Status A system status indication is displayed on this page. This status indication gives an immediate information if discharge can be started.

"Communication STATUS" Any RED indication stops “RUNNING” mode and blocks starts. "Ship signals STATUS" Any RED indication stops discharging and blocks starts. "Oil measurement STATUS" Any RED indication stops discharging. "ALARM - Disable RUNNING" RED indication stops “RUNNING” mode and blocks start. View "Alarm table" for further information about alarm status. "Analyzing unit Running STATUS" Any RED indication stops “RUNNING” mode and blocks starts. "Analyzing unit Pressure sensor" A Pressure transmitter connected to the output of the sample pump is used to measure and protect the ODME from pump blockages or starvation. "Disable Pressure check" Activate, YELLOW indication, to disable pressure transmitter protection above. A RED flashing indication will be shown to the right. Only to be used in case of pressure transmitter malfunction This selection needs to be verified on a popup window. "Measuring cell Water sensor" A Water sensor in the Measuring Cell is used to protect the sample pump from

starvation. "Disable Water check" Activate, YELLOW indication, to disable water checking. A RED flashing indication will be shown to the right. Only to be used in case of water check malfunction. This selection needs to be verified on a popup window. "Converting unit Motor sensors" Sample pump Motor sensors (when applicable) in a Converting unit fitted with

motor performance monitoring, used to protect the indicated sample pump from malfunctions and also to further protect the pump from blockages and starvation.

“Disable Motor check” Activate, YELLOW indication, to disable Converting unit motor sensors. A RED flashing indication will be shown to the right. Only to be used in case of motor sensor malfunction. This selection needs to be verified on a popup window.

Extended Converting unit only.


7.3. Alarm Table

"Alarm Reset" Resetting alarms. Status columns indicates "ACTIVE" for alarm not yet resets and "RESET" for remaining alarms already reset. "Operate" Go to "Operate page". "MENU" Go to "Main Menu".


7.4. Recorded data The recording device is formatted electronically as mentioned in MEPC.108(49) chapter 6.9.1. Recorded date is stored in a non-volatile memory and can hold approximately 3,000,000 printouts which is more than sufficient to meet the requirements. Optionally a paper printer can also be installed in the computer unit. The recorded data should be retained for at least three years. The recorded data can be copied to a USB-memory stick. See chapter 7.5. USB, page 56.

The "Recorded Data" table shows printouts as specified in MEPC.108(49), chapter 6.9.

The RED "Scroll back! ### sec" is shown if latest printout is not shown on top line. After 300 seconds (5 minutes) of inactivity, indications will go back to displaying the top line. The indication (Man) after “Conc”, “Flow”, “Speed” and GPS coordinates indicates that all values are in manual. The two screenshots above have different (Man) settings. The indication (Man) after “Conc” also indicate that the Oil Concentration was set to manual before starting for discharge, thus the sample pump will not be started. The indication (MaR) after “Conc” indicate that the Oil Concentration was set to manual after starting for discharge, (in “RUNNING” mode). Then the sample pump is started and normal pressure checks are made.

An activated alarm is indicated with “/Alarm”.

A deactivated alarm is indicated with “\Alarm”.

Printout 126627-126624: Values are set to manual.

Printout 126619-126613: Standard printout.

Mar.Dist. FO – DMA Indicate the oil type.

RED “Manual Override” Indicate a manual setting.

The overboard discharge control is disabled. Discharge stops because the total quantity of oil discharge has reached is allowed maximum.

Valve feedback indicating that the valve is closed.

Indicating that the top line is not displayed.


7.4.1. Recorded data examples Below are some examples of recorded data. Lines of recorded data contains, from the left: a printout line number, date, time and event. The date “2018-11-15” means: year 2018, month 11 = November, day 15. The time “17:33:25” means: hour 17, minute 33, second 25. The event is indicated by the 40 rightmost characters on a line. At power on some data and settings are recorded as shown below: 126710 2018-11-10 11:09:35 Power On, Power Off: 2018-11-10 11:07:17

126711 2018-11-10 11:09:35 Program Version: 2.201p3

126712 2018-11-10 11:09:35 Sample Pump: Nikuni 32MED22

126713 2018-11-10 11:09:35 PumpMotorDisconnect: NoManualSwitch

126714 2018-11-10 11:09:35 ConvertingUnitType: PumpFeedback

126715 2018-11-10 11:09:35 Flushing: Controlled Water Valve

126716 2018-11-10 11:09:35 Override: Override and OBV Valve Outputs

126717 2018-11-10 11:09:35 Line#1: Cargo,EL1,ZF1,S1

Both “Power On” and “Power Off” time are records as well as “Program Version”, “Sample Pump” type and other settings. “Automatically recorded data” that should be recorded at intervals specified in MEPC.108(49) chapter 6.9.3 can also be printed manually by selecting the “Record MEPC.108(49) 6.9.3.8” key on previous page. 126718 2018-11-10 11:10:04 - OIL DISCHARGE STARTS -

126719 2018-11-10 11:10:04 Line#1: Cargo,EL1,ZF1,S1

126720 2018-11-10 11:10:20 -- Manual Printout --

126721 2018-11-10 11:10:20 57°43.147'N 012°00.523'E

126722 2018-11-10 11:10:20 Flow 1003m3/h, Speed(Log) 10.2kn

126723 2018-11-10 11:10:20 Oil Disc 0.0L/nm, Tot 0L,Max 131L

126724 2018-11-10 11:10:20 Conc 0ppm,Mar.Dist. FO-DMA

126725 2018-11-10 11:10:20 Line#1:DISCHARGE DISABLED

126726 2018-11-10 11:10:20 Line#1:VALVE CLOSED

Line 126718 “Start Discharge” key has been pressed and system goes into “RUNNING” mode. Line 126719 indicate setting of selected discharge line, overboard control, flow input and line selection outputs. Line 126720 indicate that the records after are printed on a manual command. Line 126721 show the ships position from the ships GPS. Line 126722 show the flow in the overboard line measured by the flow meter and the ships speed from the speed log. Line 126723 show the calculated oil discharge, the total amount of discharged oil and the maximum allowed amount. Line 126724 show the measured oil concentration and the selected oil type. Line 126725 show the selected overboard line and the overboard discharge control status. Line 126726 show the selected overboard line and the indication of the overboard valve feedback. The valve is closed. “Automatically recorded data”: 126741 2018-11-10 11:11:10 - MANUAL OVERRIDE VALVE STARTS -

126742 2018-11-10 11:11:11 /Alarm - Manual Override Valve

126743 2018-11-10 11:11:11 12°34.567'N 123°45.678'E (Man)

126744 2018-11-10 11:11:11 Flow(Man) 1000m3/h, Speed(Man) 10.0kn

126745 2018-11-10 11:11:11 Oil Disc 10.0L/nm, Tot 1L,Max 131L

126746 2018-11-10 11:11:11 Conc(MaR) 100ppm,Mar.Dist. FO-DMA

126747 2018-11-10 11:11:11 Line#1:DISCHARGE ENABLED

126748 2018-11-10 11:11:11 Line#1:VALVE OPEN

126749 2018-11-10 11:11:11 Alarm - Manual Override Valve

126750 2018-11-10 11:11:19 - ALARM RESET -

126751 2018-11-10 11:11:31 - MANUAL OVERRIDE VALVE ENDS -

126752 2018-11-10 11:11:31 \Alarm - Manual Override Valve

Line 126741 show that the overboard valve control is set to manual. Line 126742 show with the initial “/Alarm” the time that the alarm overboard valve in manual is activated. Line 126743 and 126744 show that position, flow and speed are inserted manually by succeeding “(Man)” indications. Line 126745 show that the oil concentration was inserted manually by a succeeding “(MaR)”. It also shows that its mode was selected after the discharge was started. If manual mode is selected before discharge is started the indication after “Conc” is “(Man)” and in this case the sample pump is not started and communication with the measuring cell is ignored. Line 126749 show that the overboard valve is in manual. All active alarms are printed on a standard printout. Line 126750 show that the “Alarm Reset” key has been activated. Line 126751 show that overboard valve control is set back to automatic. Line 126752 show with the initial “\Alarm” the time that the alarm overboard valve in manual is deactivated.


7.5. USB The recording device is formatted electronically as mentioned in MEPC.108(49) chapter 6.9.1. Recorded data is stored in a non-volatile memory and can hold approximately 3,000,000 printouts. Recorded data can be copied to a USB-memory stick. Use a USB-stick with a Windows FAT32 file system. (Most memory sticks are preformatted with FAT32) For information regarding Recorded data see chapter 7.4.1. Recorded data examples page 55. 7.5.1. USB-Memory stick Indications before a USB-Memory stick is inserted.

Insert USB-stick here!


Indications after a USB-Memory stick is inserted.

"USB-Memory Stick report" Indicates if a USB-Memory stick is attached or not on its "Status" line. When a USB-Memory stick is found the other 3 keys becomes highlighted. "Save Printouts on USB stick" Copy the printer file to the USB-Memory stick. A new menu opens up with selections of how many printer lines to copy. The copy of the printer file will be stored in the root directory of the USB-Memory stick. The file name is "CTB-#_printer.txt" "Save Setup & Zero Cal. on USB stick" Copy the Setup file and the zero calibration files to the USB-Memory stick. The Setup file contains all settings made from the touch screen. The file name is "CTB-#_setup.txt" The Zero calibration file contains the result from the latest successful calibration. The file name is "CTB-#_zero.txt" "Press before removing USB-Stick" IMPORTANT! Press this key before removing the USB-Memory stick. The "Status" line will show when the stick is unmounted and can be removed. If the USB-stick is removed before this key is pressed, power must be switched off and on again before the Computer Unit can recognize a USB-stick again.


7.5.2. Save Printouts on USB stick If the printer file “CTB-####_printer.txt” already exist on the USB-stick an overwrite verification popup is displayed.

Select how many printouts to save on the USB-stick.


7.6. On-board Test This chapter refers to ANNEX 14, RESOLUTION MEPC.108(49) chapter 12. 12 ON-BOARD FUNCTIONAL TEST AND CHECKOUT PROCEDURE The functional test referred to in paragraph 9.1.8 should include at least all the following tests when the monitoring system is operating on water:

.1 verify correct running of pumps, absence of leakage in the sample pumping and piping system, correct functioning of remote-controlled sampling valves, etc. .2 verify by checking flow rates or pressure drops, as appropriate, that the system operates under correct flow conditions. This test should be repeated separately for each sampling point;

.3 verify that alarms function correctly when a malfunction occurs external to the monitoring system, such as no sample flow, no flow meter signal, power failure, etc.; An external malfunction can be checked by disconnecting power to the converting unit. Then communication alarms will be raised.


.4 vary the simulated input signals manually while the monitoring system is operating on water and check the recordings for correct values and timing. Vary the simulated manual input signals until alarm conditions are obtained, and verify proper recordings. Ascertain that the overboard discharge control is activating and verify that the action is being recorded; .5 verify that normal operating condition can be reset when the value of the instantaneous rate of discharge is reduced below 30 liters per nautical mile;


.6 activate the manual override control and verify that a recording is made and that the overboard discharge control can be operated;

.7 turn off the system and verify that the overboard discharge valve closes automatically or the relevant pumps are stopped and the overboard discharge control is inoperative;


.8 Only in connection to renewal of ship´s IOPP Certificate, if a new measuring cell has not been installed, the following should be performed. Start up the system and check the zero and gain settings for the oil content meter in accordance with the manufacturer's operations and technical manual;

.9 check the accuracy of the flow meter(s), for example by pumping water in a loop where the flow rate may be calculated from the level change in a tank. The check should be made at a flow rate of about 50% of the rated flow of the flow meter.


7.7. Measuring Cell Check/Calibration 7.7.1. Zero Calibration Status Indicates the Zero Calibration status of the connected Measuring Cell.

The graph indicates eight different values measured in the Measuring Cell. Values from the left are: #1 internal reference, #2-6 photo diodes, #7 water detector, #8 temperature. The upper red line is the high limit and the lower red line indicates the low limits for accepting as fresh water (0 ppm). Values outside of accepted areas are indicated by a red light and inside by a green light. Measured values (Readings) and limits are also displayed numeric below the graph. "Measuring Cell info:" "Serial no" Serial number of the connected Measuring Cell. "Factory Calibration" Factory calibration time of the connected Measuring Cell. "Zero Calibration status:" Calibration status. "Last Successful Zero" Display the time of the last successful Zero Calibration of the connected Measuring Cell. Unsuccessful trials are not indicated here. "Use Zero Cal. result" Selection if the Zero Calibration Result is used in the concentration calculations. Graphs "Last Successful Zero" Displays the values from the last successful zero. "Is values" Displays the measured values.


7.7.2. Zero Calibration Prepare Zero Calibration can be performed in 2 different ways. If the installation has a "Controlled Water Valve" this fresh water can be used for calibration. If not, water has to be manually poured into the Measuring Cell. When "Zero Prepare" is pressed the tabs "Status”,”Prepare",...,"Picture" are no longer visible. Flush Manual:

Flush Auto:

"Flush Manual/Auto" Press this key to toggle between manual flushing and automatic flushing by the "Controlled Water Valve". If "No Controlled Water Valve" is selected in the Setup/Config-page this key is not visible. "Zero Prepare" Press this key to start preparations for Zero Check/Calibration.


7.7.3. Zero Calibration Take Zero When "Zero Prepare" is pressed the tabs "Status","Prepare",...,"Picture" are no longer visible. Flush Manual:

Flush Auto:

"Take Zero (KB)" Press this key to start Zero Check/Calibration. Reading are analyzed for 60 seconds. "Time" Counting down seconds while readings are analyzed. "Square indication" Indicates the result of the Check/Calibration, red = fail / green = ok. "Graph indication" See explanation 2 pages up when where Status is explained.


7.7.4. Replace Measuring Cell The instructions on the 2 pages below describes how the Measuring Cell is replaced and the tools needed.

Before replacing the measuring cell, study the chapter 4.10. Measuring Cell Instructions and Replacement page 30.


7.8. Setup of parameters In each system setting the system details are selected by pressing indicators with white background or keys. To enter the “Setup”-page you should first use: Password: "3" and "Admin". Greyed out indications and keys cannot be changed without giving the password for “Restricted Settings”. Password: “8515 and “Admin”. Caution must be taken before changing setup settings. Changes are recorded at the time of change and on normal printouts. 7.8.1. Line of discharge The system handles a maximum of 4 discharge lines but maximum of 2 overboard valves

"Line Name" Name of each overboard line. Drop down list below: "Not Used" Line is not used. " " 30 L/nm alarm mode, line has no name. "Cargo" 30 L/nm alarm mode, line name is "Cargo". "Stripping" 30 L/nm alarm mode, line name is "Stripping". "Slop" 30 L/nm alarm mode, line name is "Slop". "Dirty Ballast" 30 L/nm alarm mode, line name is "Dirty Ballast". "Clean Ballast" 15 ppm alarm mode, line name is "Clean Ballast". "Valve Control" Hardware relay output and input. "None" No valve control. "EL1" Relay output on terminals 3 and 4 in Computer Unit. Feedback input on terminals 26 and 27 in Computer Unit. Closed contact indicating open overboard valve. "EL2" Relay output on terminals 5 and 6 in Computer Unit. Feedback input on terminals 28 and 29 in Computer Unit. Closed contact indicating open overboard valve. "EL1-ZD1" Relay output on terminals 3 and 4 in Computer Unit. Feedback input on terminals ZD1 in Converting Unit. Closed contact indicating open overboard valve. "EL2-ZD2" Relay output on terminals 5 and 6 in Computer Unit. Feedback input on terminals ZD2 in Converting Unit. Closed contact indicating open overboard valve. "EL1-INV" Relay output on terminals 3 and 4 in Computer Unit. Feedback input on terminals 26 and 27 in Computer Unit. Open contact indicating closed overboard valve. Closed contact indicating closed overboard valve. "EL2-INV" Relay output on terminals 5 and 6 in Computer Unit. Feedback input on terminals 28 and 29 in Computer Unit. Open contact indicating closed overboard valve. Closed contact indicating closed overboard valve. "EL1/EL2" Open a key in “Operate”-menu to manually control the slop tank valve output. Relay output on terminals 3 and 4 in computer unit controls the overboard valve.


Relay output on terminals 5 and 6 in computer unit controls the slop tank valve. Feedback input on terminals 26 and 27 in computer unit for the overboard valve. Feedback input on terminals 28 and 29 in computer unit for the slop tank valve. Closed contact indicating open overboard valve / slop tank valve. Drawings for this setting are, on request, and not included in this manual "EL1/EL2-n" Open a key in “Operate”-menu to manually control the slop tank valve output. Relay output on terminals 3 and 4 in computer unit controls the overboard valve. Relay output on terminals 5 and 6 in computer unit controls the slop tank valve. Feedback input on terminals 26 and 27 in computer unit for the overboard valve.

Closed contact indicating open overboard valve, no feedback indication for the slop tank valve.

Drawings for this setting are on request, and not included in this manual "Flow Input" Actual flow meter. "None" No flow meter for this line. "ZF1" ZF1 input on Zener Barrier PCB is used. "ZF2" ZF2 input on Zener Barrier PCB is used. "CVF" CVF input on Converting Unit PCB is used. "ZF1->ZF2" ZF1 input on Zener Barrier PCB is used but calculations are setup in ZF2-page. "Selection Output" Hardware relay output to activate when line is selected "None" No hardware relay output for this line. "S1" Relay output on terminals 5 and 6 on Converting Unit PCB. "S2" Relay output on terminals 7 and 8 on Converting Unit PCB. "S1&S2" Both relay outputs above are activated. 7.8.2. ZF1 (Zener barrier flow input 1)

"Flow ZF1" Is value, calculated flow. "Flow High limit" High flow limit. "Flow Low limit" Low flow limit. "Alarm delay" Alarm delay. "Alarm timer" Alarm time to count down the alarm delay. "Input current" Measured current on ZF1 input. "Flow at 4mA" Corresponding flow for current input of 4 mA. "Flow at 20mA" Corresponding flow for current input of 20 mA. "Square root" NO if current is linear to flow, YES if current is linear to pressure. 7.8.3. ZF2 Same as ZF1 above. 7.8.4. CVF Same as ZF1 above.


7.8.5. Pressure

Refer to chapter 4.8. Pressure alarm settings page 24 for suggestions of limit settings. The function of the pressure alarms is explained below, see chapter 7.8.5.1. Static Pressure/Water function page 69. "Pressure" Is value, calculated pressure. "Static Pressure" Measured counter pressure from overboard line. "Water High limit" High pressure limit from fresh water. "Water Low limit" Low pressure limit from fresh water. "Sample High limit" High pressure limit from sample pump. "Sample Low limit" Low pressure limit from sample pump. "Input current" Measured current on Pressure input. "Pressure at 4mA" Corresponding pressure for current input of 4 mA. "Pressure at 20mA" Corresponding pressure for current input of 20 mA. 7.8.5.1. Static Pressure/Water function The pressure alarms compare the actual pressure with the pressure measured from the overboard line before the sample pump was started or the fresh water valve was opened. Assume that the unit is started without flushing and the start is normal without any alarms. The process for checking the sample pressure limits then becomes:

1. Measure the “Pressure” in the analyzing unit. This will be the same pressure as in the overboard line because the inlet and outlet pipes to the overboard line are open.

2. The “Static Pressure” is set to the measured “Pressure”. The “Static Pressure” will not change while the sample pump is running.

3. Start the sample pump. 4. The level of pressure increase is then calculated as “pressure increase” = “Pressure” – “Static Pressure”. 5. The “pressure increase” is then compared with the “Sample High limit” and “Sample Low limit”. 6. If “pressure increase”>“Sample High limit” for 10 seconds the “Alarm – High Work Pressure” is activated and

if “pressure increase”<“Sample Low limit” for 10 seconds the “Alarm – Low Work Pressure” is activated. 7. Any of these 2 alarms will stop the unit, switch of the sample pump and close the overboard valve.

Assume that the unit is started with water flushing and the start is normal without any alarms. The process for checking the fresh water pressure limit then becomes:

1. Measure the “Pressure” in the analyzing unit. This will be the same pressure as in the overboard line because the inlet and outlet pipe to the overboard line are open.

2. The “Static Water” is set to the measured “Pressure”. The “Static Water” will not change while the water valve is open.

3. Open the water valve. 4. The level of pressure increase is then calculated as “pressure increase” = “Pressure” – “Static Water”. 5. The “pressure increase” is then compared with the “Water High limit” and “Water Low limit”. 6. If “pressure increase”>“Water High limit” for 10 seconds the “Alarm – High Water Pressure” is activated and

if “pressure increase”<“Water Low limit” for 10 seconds the “Alarm – Low Water Pressure” is activated. 7. Any of these 2 alarms will stop the unit and close the water valve.


7.8.6. Motor (Optional Extended Converting unit I/O PCB) This tab is shown only if the property “ConvertingUnitType” is set to “Extended” in the “Config” tab below, see chapter 7.8.9. System Configuration, Alarms&Extras page 71. For SPP-100 sample pump only.

"Activate heater in “StandBy" Output DC voltage between phases L1-L2 while the sample pump is not running. The motor is heated to avoid condensation in the motor. "Heater" Measured DC voltage between phases L1-L2 to heat the motor while it is not running. "SetValue" Wanted DC voltage between phases L1-L2 to heat the motor while it is not running. "Mains L1-L2" Measured AC voltage between phases L1-L2. "Min","Max" Min. and max. limits of Mains, stops discharge with an alarm delay of 10 seconds. "Current L1,L2,L3" Measured AC current on phases L1, L2 and L3. "Min","Max" Min. and max. limits of Current, stops discharge with an alarm delay of 10 seconds. “(Standby) Max” An alarm is generated if this max current is exceeded by any phase during “StandBy” mode. "Freq." Measured mains voltage frequency. "Min","Max" Min. and max. limits of freq., stops discharge with an alarm delay of 10 seconds. "Fi" Measured angle in degrees between voltage and current. Cos(fi)=0.78 => fi=39 degrees. "Min","Max" Min. and max. limits of fi., stops discharge with an alarm delay of 10 seconds. "PTC" Measured resistance of PTC resistors in motor windings. Immediately stop of both sample pump motor and heater. "Temp(pcb)" Measured temperature by sensor located on the converting unit pcb. "Max" Max. limit of pcb temperature, stops discharge with an alarm delay of 10 seconds. 7.8.7. Speed

"GPS Speed" Speed indicated by the GPS. "Log Speed" Speed measured from the speed log. "Speed High limit" High speed limit. "Speed Low limit" Low speed limit. "Input pulses" Measured pulse frequency from the speed log. "Speed Log give" Speed log pulses per nautical mile. "Speed source" Selected speed source. "Log" speed pulse log, "GPS" speed from GPS.

Showing voltage in standby if heater is on. From software ver 2.204


7.8.8. System Configuration, Standard

"CTB - Serial number" Serial number of the unit. "CPU - Serial number" Serial number of the Computer Unit PCB. "Sample Pump" Set to the installed sample pump. “SpeckPumpSerialNo” If “SamplePump” selection is “Speck Air” its serial number can be inserted to the right of the “SamplePump” selection. "Flushing Configuration" Set to the installed water flushing arrangement. "No Controlled Water Valve" No fresh water valve is controlled by the unit. "Controlled Water Valve" A fresh water valve is controlled by the unit. “Indicated Water Valve” An indicated fresh water valve is connected to the unit. Connect to ZD4. Closed contact for closed valve. "ManualOverride_OverboardValve_Output" Selection of which relay output should be activated when the key: "Manual Override Overboard Valve" is activated. Relays are in Computer Unit. See chapter 7.10.6. Power (Computer unit Power supply) page 77. “Manual Override Output” Activating “Manual Override Relay”, terminals 7, 8 and 9. Normally used to remove an external interlock. “Overboard Valve Output” Activating relay output of selected overboard line. “Override and OBV Valve Outputs” Activating both functions above. 7.8.9. System Configuration, Alarms&Extras

“ConvertingUnitType” Setting of converting unit type.

An alarm for sample pump contactor feedback in wrong position will be raised again at every touch screen timeout (about 30 minutes). This alarm is always checked for units with serial number CTB 2892 and later.


“PumpFeedback” When upgrading the software to version 2.20x it is recommended to upgrade converting units made for an electrical sample pump according to drawing, CTB110627.1el, internal cable diagram for electrical sample pump motor page 141. The computer unit monitors the feedback of the sample pump start/stop contactor position and raise an alarm if the feedback is unexpected. An open contactor (pump not running) is indicated with a closed feedback. Converting unit I/O pcb: ”CVNT_C”.

“NoPumpFeedback” Setting for units without sample pump feedback and for units with air driven sample pump. For units with an electrical sample pump it is recommended to install the pump feedback. Converting unit I/O pcb: ”CVNT_C”.

“Extended” (Option) Setting for specially equipped converting units only, with means for monitoring pump motor performance and heating the motor during “StandBy” mode. The Extended Converting unit can only be combined with the SPP-100 sample pump. Extended units have the sample pump contactor feedback wired. See drawing: CTB110627.1elext page 142. Converting unit I/O pcb: ”CVCT_B”.

“Extended-NoLim” (Option) Same as “Extended” above except for 2 disabled alarms: "62 Alarm – Sample pump Motor Phase Error" "63 Alarm – Sample pump Motor Limits". See chapter 8.9. Extended Converting unit Motor alarms (Optional) page 88.

“Freeze Risk Alarm” A freeze risk alarm is raised if the temperature in the Measuring cell is below 4°C and the water sensor is active. The alarm is raised only once and will not be activated again unless the Measuring cell temperature first has increased above 8°C.

“PumpMotorDisconnect” Support of a manual disconnector switch between the Converting unit and the sample pump motor. The computer unit can monitor the switch position. The alarm should be deselected or wired in the Converting unit. Connect to terminals 13, 14 on the Converting unit I/O pcb.

“ManualWithFeedback” The computer unit monitors the switch position and raises an alarm if the switch remains in the wrong position at touch screen timeout (about 30 minutes).

“NoManualSwitch” No disconnector switch is installed. "PaperPrinter" Select whether a paper printer is installed of not. If “NO” no printouts are made and no printer alarms are generated. If “YES” the same printouts that are made to “Recorded data” are made on the printer. Printer errors will stop overboard discharging. “ExternalModbus” (Option) A modbus RTU master that can over an RS485 line send data to other equipment. This needs a specially equipped CUIO board. Connect on terminals 44-46. Use of this optional CUIO-board is not included in this manual. Setting should normally be “No”. "VoyageDataRecorder" (Option) A NMEA sentence is sent for every line added to “Recoded data”. This needs a CUIO board of version “L” or later, connect on terminals 41-43. Setting should normally be “No”.

Note! A paper printer cannot be used together with this option. Messages are sent as "Proprietary Sentences", and their compositions are: "$PCTB","Recorded data line","*",2 bytes checksum,Carriage Return,Line Feed. Baudrate=4800, Parity=None, Data bits=8.

"Contact Information" Contact information can be displayed in the "Start menu" and in the "Alarm table".


7.9. Computer 7.9.1. USB-Memory stick To enter the “Computer”-page you should first use: Password: "1" and "User". Indications with an inserted USB-Memory stick.

"USB-Memory Stick report" Indicates if a USB-Memory stick is attached or not on its "Status" line. When a USB-Memory stick is fount the other 3 keys becomes highlighted. "Scan for New Software" Used to install new software on the unit. When pressed the root directory of the USB-Memory stick is scanned for new software. A new menu will open up with the result of the scan and installation selection.

A serial number specific password is needed for the software upgrade is provided by an authorized agent.

"Remove USB-Stick" IMPORTANT! Press this key before removing the USB-Memory stick. The "Status" line will show when the stick is unmounted and can be removed. 7.9.2. Real Time Clock Setting of the Real Time Clock. Clock shall be set to GMT-time. The clock can be set manually or to the time read from the GPS.


7.9.3. IP-address If the unit is connected to the local area network on the vessel it normally by a wired ethernet connection. One this page a static IP-address or IP-address received through DHCP can be selected.

7.9.4. Touch Screen Calibration

If the touch screen is not in a working condition or behaving strange, a calibration might solve the problem.

If it is impossible to maneuver to the touch screen calibration page by using the touch screen itself it is possible to

connect a USB mouse to the USB port at the front of the computer unit.

Select the “Calibrate Touch Screen” key and the touch screen calibration display appears:

Press your finger tip (do NOT use the USB-mouse) against the yellow circle. When the touch screen has accepted your input, the circle moves to the next calibration point. Press your finger tip against the yellow circle again and so on. To exit without calibrating the screen, wait until the red bar at the bottom of the screen has disappeared and the calibration screen will close. If the calibration is successful the new calibration should be in effect directly after exit from the calibration screen. In some cases, the unit has to be restarted. Do this by disconnecting power and connecting it back on again.


7.10. System Check To enter the “System check”-page you should first use: Password: "2" and "Admin". Status of communication with printed circuit boards in computer, converting unit and analyzing unit. NMEA (GPS) transmitter data. Testing of relay output and digital inputs. Testing of printer port. Activation and deactivation of Expiry. 7.10.1. Main Overview of printed circuit boards in the system.

7.10.2. Test

"Test Mode" Press to activate. When activated, relay outputs of other printed circuit boards in the system can be manually activated. Take caution when starting the sample pump, pressure alarms are disabled. Password: "8378" and "Admin".


7.10.3. GPS (NMEA 0183 receiver) Display of the transmitted NMEA sentences from the GPS. Any of the sentences RMC, GLL or GGA must be received to get the ships GPS position. If the ship speed is taken from the GPS the RMC or VTG sentences must be received.

“NMEA_String” Showing a buffer containing about the last 600 received characters. "RMC" Showing the last RMC sentence, the RMC sentence contains GPS position, ships speed, date

and time. "GLL" Showing the last GLL sentence, the GLL sentence contains GPS position. "GGA" Showing the last GGA sentence, the GGA sentence contains GPS position. "VTG" Showing the last VTG sentence, the VTG sentence contains ships speed. "Pause Display" Press to stop updating the "NMEA_String" and the different sentences. To make it easier to manually read out data. 7.10.4. Paper Printer _(Optional) The paper printer module mounted to the right inside the computer unit. The unit includes a thermal paper printer and a paper rewinder mounted on a frame that fits to the right inside the computer unit. Item d2 on drawing: CTB10001p sheet 3, Computer Unit with open door page 98.

"PrinterCommStatus" Communication status with the paper printer module. "ActivateWinder" Activate the paper rewinder. "Print test line" Makes a test printout to the paper printer.

Timeout of 45 sec for each one of the sentences.


7.10.5. Expiry (Trial period) A trial period of a number of days, normally 30 or 60, can be activated. When the trial period has expired the system can no longer be started to discharge the slop. The status of an enabled trial period is also displayed at the bottom of the “Main Menu”. The number of days, hours, minutes and seconds until expiry is shown. Expiry codes can only be generated by the maker. All units have a unique code.

"Set Expiry" Normally activated by maker or by agent. A special code is needed to enable the trial period. "Set Extra Expiry" A code for extending the trial period. Normally inserted by the end customer. The code for Extra Expiry can only be used once. "Remove Expiry" A code for removing the trial period. 7.10.6. Power (Computer unit Power supply) The power unit in the computer unit. Item d1 drawing CTB10001p sheet 3, Computer Unit with open door page 98.

"PowerCommStatus" Communication status with the power supply. "PowerOut" Relay outputs of the power supply "PowerFlags" Software version, temperature and flags status of the power supply. "PowerTxData" Transmit data to the power supply. "PowerRxData" Received data from the power supply.


7.10.7. CUIO (Computer unit I/O PCB) The Input/Output printed circuit board (PCB) in the computer unit (CUIO). Item d5 drawing CTB10001p sheet 3, Computer Unit with open door page 98.

"CUIO_I/O_Status" Communication status with the CUIO PCB. "CUIO_In" Status of digital inputs of the CUIO PCB. "Log" Input data from the speed log connected to the CUIO PCB. "Buzzer" Buzzer output on the CUIO PCB. "CUIO_OutData" Output data to the CUIO PCB. "CUIO_InData" Input data from the CUIO PCB. 7.10.8. CVCT/Standard (Converting unit I/O PCB) The Input/Output printed circuit board (PCB) in the converting unit (CVCT). Item d5 drawing CTB10003 sheet 3 of 4, Converting Unit page 102.

"CVCT_CommStatus" Communication status with the CVCT PCB. "CVCT_Out" Relay outputs of the CVCT PCB.

Refer to Chapter 5. Start/Stop procedure page 38 before activation of pump or water.

"CVCT_In" Software version, digital inputs and current input of the CVCT PCB. "CVCT_TxData" Transmit data to the CVCT PCB. "CVCT_RxData" Received data from the CVCT PCB.


7.10.9. CVCT/Extended (Optional Extended Converting unit I/O PCB) The Extended Input/Output printed circuit board (PCB) in the converting unit (CVCT).

“CVCT_SH_Out” Relay outputs of the Extended CVCT PCB. “CVCT_SH_In” Input and Output data on the Extended CVCT PCB. 7.10.10. ZBCT (Converting unit Zener Barrier PCB) The Zener Barrier printed circuit board (PCB) in the converting unit (ZBCT). Item d6 drawing CTB10003 sheet 3 of 4, Converting Unit page 102.

"ZBCT_CommStatus" Communication status with the ZBCT PCB. "ZBCT_Out" Selection of power to ZF1 or ZF2 current input. "ZBCT_In" Software version, digital inputs ZD1 - ZD4, analogue input of channels ZP, ZF1 and ZF2. Voltage levels and temperature on the ZBCT PCB. "ZBCT_TxData" Transmit data to the ZBCT PCB. "ZBCT_RxData" Received data from the ZBCT PCB.


7.10.11. MC (Measuring Cell) Readings from the measuring cell. The cell is connected to the Zener Barrier PCB.

"MC_CommStatus" Communication status with the MC. "MC_Info" Indicates software version, serial number and more communication status. "CalRd_Com" Communication status of reading calibration from with the MC. "GainIn" Internal use. "MC_IR" Internal use. "MC_Ain" Internal use. 7.10.12. External Modbus RTU (Optional CUIO) Modbus RTU communication over an RS485 channel on the CUIO PCB in the Computer unit. Intended for communication with the Cargo Control system. This option is not further described in this manual.


7.11. Approvals Indicating approvals of the Cleantrack1000B. The menu below shows the approvals of a unit upgraded to a total of 10 bio-fuel blends.

The menu below shows the approvals of a unit approved for the 5 bio-fuels blends according to MEPC.1/Circ.761.

“Upgrade” If adaption for additional bio-fuels is needed, another serial number specific

activation password can be purchased from an authorized agent. Select the “Upgrade” key and insert the activation password in the popup menu.


8. Fault-finding The computer program contains functioning resulting in a number of alarms for internal malfunctions and abnormal operational conditions. This section gives a summary of the functioning and, where appropriate, how the alarms are used in fault-finding. The information given is useful for experienced computer and electronic engineers as well as for the operator in fault-finding of the entire system. This section contains essentially descriptive and explanatory information. Guidance to trouble shooting based on the computer alarm indications is given below.

8.1. Malfunction of Computer/Converting unit In case of serious malfunction of either the Computer unit or the Converting unit, disconnect power supply to the units. Always keep power supply to Converting unit disconnected if its functioning cannot be monitored by the Computer unit, regardless of whether the malfunction is in the Converting unit or in the Computer unit. Contact an approved agent for service.

8.2. List of displayed alarms 0 System - Setup file Key error 1 System - Setup file Read error 2 System - Setup file Write error 3 System - Acc total file Key error 4 System - Acc total file Read error 5 System - Acc total file Write error 7 System – Setup error #101 Valve Control 10 System - Ref Error Measuring Cell 12 System - Reading Cal Data 13 System - Comm. error Computer Power PCB 14 System - Comm. error Converting I/O PCB 15 System - Comm. error Zener Barrier PCB 16 System - Comm. error Measuring Cell 17 System - Computer I/O error 18 System - Replaced Measuring Cell? 19 System - Invalid MC values. 20 Alarm - NMEA (GPS) receiver timeout. 21 Alarm - Low Flow 22 Alarm - High Flow 23 Alarm - Low Speed 24 Alarm - High Speed 25 Warning - Valve Open no feedback 26 Alarm - Valve Close no feedback 27 Alarm - Slop Valve Open no feedback 28 Alarm - Slop Valve Close no feedback 29 Alarm - GPS Speed timeout 30 Alarm - High Conc. > 1000 ppm 31 Alarm - Discharge > 30 l/nm 32 Alarm - Max Accumulated Total Oil 36 Alarm - Oil conc. > 15 ppm 37 Alarm - Manual Override Valve 38 Warning - Oil Concentration in Manual 39 ON-BOARD FUNCTIONAL TEST ALARM 40 Alarm - High Work Pressure 41 Alarm - Low Work Pressure 42 Alarm - No water in Measuring Cell 43 Alarm - High Water Pressure 44 Alarm - Low Water Pressure 45 Alarm - Overcurrent 46 Alarm – High Pump Temperature 47 Alarm - Indicating Flushing Water 50 Alarm – Printer Busy 51 Alarm – Printer Busy (Xoff)


52 Alarm – Printer Feedback Error 53 Alarm – Printer Cover Open 54 Alarm – Printer Paper End/Cover Open 55 Alarm – Printer Head Temp Error 56 Alarm – Printer Voltage Error 57 Alarm – Printer Feedback Missing 58 Alarm – Printer Buffer Overflow 60 Alarm - Sample Pump Motor PTC Overheat 61 Alarm - Sample Pump Motor PTC Shortcut 62 Alarm - Sample Pump Motor Phase Error 63 Alarm - Sample Pump Motor Limits 64 Alarm - Sample Pump Motor Heater 66 Alarm - Sample Pump Running feedback 67 Alarm - Sample Pump no Running feedback 68 Alarm - Work Pressure after Pump Stop 69 Alarm - Freezing risk Measuring cell 70 Warning - VALVE OPENED, Line#1 71 Warning - VALVE OPENED, Line#2 72 Warning - VALVE OPENED, Line#3 73 Warning - VALVE OPENED, Line#4 74 Alarm - Pump Disconnector Switch is ON 75 Alarm - Pump Disconnector Switch is OFF

8.3. System file errors The unit cannot run with one of these alarms remaining. "0 System - Setup file Key error" Error in the content of the programmed setup data. At least one setting need to be changed before this alarm can be reset. Check all settings or consult a service engineer for corrective actions. "1 System - Setup file Read error" File system error while reading the setup data. Consult a service engineer for corrective actions. (Computer CPU printed circuit board need to be replaced.) "2 System - Setup file Write error" File system error while writing the setup data. Consult a service engineer for corrective actions. (Computer CPU printed circuit board need to be replaced.) "3 System - Acc total file Key error" Error in the content of the saved accumulated oil content data. Reset total oil discharged. See chapter 7.2.2. Running Settings, page 47. Reset the alarm. "4 System - Acc total file Read error" File system error while reading the content of the accumulated oil content data. Consult a service engineer for corrective actions. (Computer CPU printed circuit board need to be replaced.) "5 System - Acc total file Write error" File system error while writing the content of the accumulated oil content data. Consult a service engineer for corrective actions. (Computer CPU printed circuit board need to be replaced.) “7 System - Setup error #101 Valve Control” File system error indicating a compatibility error in “Valve Control” of “Line” data in the “Setup” menu. Settings “EL1/EL2” and “EL1/EL2-n” can only coexist together with “None”. Reprogram this setting or consult a service engineer for corrective actions.


8.4. System communications errors The Computer PCB (master) is communicating with the Computer Power supply, the Converting unit I/O and the Zener barrier PCB that also transmits data to and from the Measuring Cell. The communication is Modbus RTU over an RS485 line at the speed of 19200 baud. The Zener barrier PCB and the Measuring Cell has a special 2-wire connection. The Measuring cell is powered through the same 2-wires as where the half duplex communication is going on See chapter 3.2. Scope of Supply and System Supplies page 9 and chapter 8.11. Indications on PCB's, page 90 for locating PCB's (Printed Circuit Boards) in text below. For light emitting diode indications, see chapter 8.11. Indications on PCB's page 90. When a communication error occurs the communication wiring, power supply wiring and fuses must be checked. The unit cannot run with one of these alarms remaining. Press the "Alarm Reset"-key in the "Alarm Table" to reset the alarm and try to fix the fault. See chapter 7.3. Alarm Table, page 53. "10 System - Ref Error Measuring Cell" An internal error on the IR-measurement readings in the Measuring Cell. Normally the Measuring Cell needs to be replaced. Note that the communication to the ZBCT must work before this communication failure can be solved. "12 System - Reading Cal Data" The Computer CPU failed to read the Measuring Cell calibration data. Check the connection between the Zener barrier PCB (ZBCT) and the Measuring cell. This is a special 2 wire connection. The measuring cell is powered on the same 2 wire as where the communication is done. Note that the communication to the ZBCT must work before this communication failure can be solved. For light emitting diode indications, see chapter 8.11.4. Zener barrier PCB indications page 91 "13 System - Comm. error Computer Power PCB" Computer CPU failed to communicate with the Computer power supply. This is a Modbus RTU communication over an RS485 line at the speed of 19200 baud. Check the flat cable connections in the Computer unit cabinet. There are 2 flat cables, the 34 pole flat cable with grey contacts that connects the Computer CPU PCB with the Computer I/O CPU (CUIO) and the 14 pole flat cable with red contacts the connects the Computer Power supply with the Computer I/O CPU. "14 System - Comm. error Converting I/O PCB" Communication error between the Computer CPU and the Converting unit I/O PCB. This is a Modbus RTU communication over an RS485 line at the speed of 19200 baud. Check the connection between the Computer unit and the Converting unit. Check also setting of property “ConvertingUnitType”,

see chapter 7.8.9. System Configuration, Alarms&Extras page 71. For light emitting diode indications, see chapter 8.11.2. Converting unit I/O PCB indications page 90. Keep the Converting unit powerless until the error can be fixed. "15 System - Comm. error Zener Barrier PCB" Communication error between the Computer CPU and the Converting unit I/O PCB. This is a Modbus RTU communication over an RS485 line at the speed of 19200 baud. Check the connection between the Computer unit and the Converting unit. Check the flat cable between the Converting unit I/O PCB and the Zener barrier PCB inside the Converting unit. For light emitting diode indications, see chapter 8.11.4. Zener barrier PCB indications page 91 "16 System - Comm. error Measuring Cell" Communication error between the Computer CPU and the Measuring cell. Check the connection between the Zener barrier PCB and the Measuring cell. Check communication to the Zener barrier PCB to work before fail searching this error. Normally at least one light emitting diode on the Measuring Cell is lit. "17 System - Computer I/O error" Communication error between the Computer CPU and the Computer I/O PCB. Check the flat cable connections inside the Computer unit. "18 System - Replaced Measuring Cell?" If the Measuring Cell is replaced while power is connected to the Computer Unit, it will give this alarm.


Reset the alarm to acknowledge. “19 System - Invalid MC values” Readings from the Measuring Cell are not valid. Reset the alarm to acknowledge. The alarm is expected to disappear after a reset. If not, the Measuring Cell needs to be replaced.

8.5. External sensor alarms Refer to drawing CTB110204.1el/pn for electrical connections. "20 Alarm - NMEA (GPS) receiver timeout”

This alarm is generated if the NMEA signal drops out. Expected communication speed is 4800 baud. The unit listens for four different NMEA sentences:

1. RMC, containing GPS position, ships speed, time and date. 2. GLL, containing GPS position 3. GGA, containing GPS position 4. VTG, containing ships speed

If neither RMC, GLL nor GGA containing position is received this alarm will be generated. To be able to get the ships speed information from the GPS the RMC or VTG must be received. Check the connection of the NMEA transponder to the Computer unit. See chapter 7.10.3. GPS (NMEA 0183 receiver) page 76.

"21 Alarm - Low Flow" "22 Alarm - High Flow"

This alarm indicates a flow that is above the “High Flow” limit or below the “Low Flow” limit. Check the connection of the 2-wire flow connection on terminals ZF1 or ZF2 on the Zener barrier PCB in the Converting unit. Flow meter is normally connected to ZF1. Flow meter selection and scaling is made in the "Setup"-menu. See chapter 7.8.1. Line of discharge page 67 for actual selection and the following pages for scaling. The transmitter is a 2-wire, 4-20 mA with 24 VDC supply. The voltage should be between 16 VDC and 25 VDC. It is only the selected flow input that has the 24 VDC power enabled. Note that these alarms are disabled if flow is in manual mode.

"23 Alarm - Low Speed" "24 Alarm - High Speed" This alarm indicates a ships speed that is above the “High Speed” limit or below the “Low Speed” limit. Check that the Speed source selection is correct, Pulse log or GPS. If source is GPS, check that the NMEA communication from the GPS works. If source is Pulse log, check the connection and the programming of pulses / hour. See chapter 7.8.7. Speed page 70 "25 Warning - Valve Open no feedback" "26 Alarm - Valve Close no feedback"

This is a Warning (Open)/Alarm (Close), indicating that the overboard valve position feedback signal has not acknowledged the output signal within the timeout. The timeout is selectable up to 60 seconds. The overboard valve may be in the wrong position due to some part of the overboard valve control or the power supply for the valve control system has failed. Or the valve is in the correct position by the feedback signal fails. The overboard valve is controlled by the overboard valve relay output in the computer unit. Check the fuse(s) for the overboard valve and both the output and the feedback connections. Refer to drawing CTB110204.1el/pn.

“27 Alarm - Slop Valve Open no feedback” “28 Alarm - Slop Valve Close no feedback”

The slop tank valve position feedback signal has not acknowledged the output signal within its timeout. The timeout is programmable in the “Setup”/”Line” menu. This alarm can only be generated for the “Valve Control” setting“EL1/EL2”. The slop tank valve may be in the wrong position due to some part of the slop tank valve control or the power supply for the valve control system has failed. The slop tank valve is controlled by the “EL2” relay output in the computer unit. Check the fuse(s) for the relay output the feedback connections.

“29 Alarm - GPS Speed timeout”


Source for the ships speed sis selected to “GPS” but neither the sentence “RMC” or “VTG” is received correctly. Refer to alarm 20 above for faultfinding.

8.6. Measurement alarms The unit closes the overboard valve and does not discharge with any of the alarms 30-36 below active. Press the "Alarm Reset"-key in the "Alarm Table" to reset the alarm. See chapter 7.3. Alarm Table, page 53. "30 Alarm - High Conc > 1000 ppm" Measured oil concentration is above the measuring range of 1000 ppm. "31 Alarm - Discharge > 30 l/nm" Measured oil discharge is above 30 l/nm. "32 Alarm - Max Accumulated Total Oil" Discharged oil has reached the programmed maximum total oil discharge. For setting of total oil, see chapter 7.2.2. Running Settings, page 47. "36 Alarm - Oil conc. > 15 ppm" The unit is in oil concentration mode (15 ppm mode). Measured oil concentration is above 15 ppm. "37 Alarm - Manual Override Valve" This alarm is generated when the "Manual Override Overboard Valve" key is activated. "38 Warning - Oil Concentration in Manual"

This alarm is generated at an interval of 10 to 20 minutes if the unit is in “RUNNING” mode (Discharge Started) and Oil Concentration is in “Manual”.

"39 ON-BOARD FUNCTIONAL TEST ALARM" This alarm is generated when the "GENERATE ALARM" key is activated in the "On board test" .3 page.

8.7. Measurement sample alarms "40 Alarm - High Work Pressure" High sample water pressure in the analyzing unit for 10 seconds. It indicates a problem on the outlet side of the analyzing unit. “RUNNING” mode is stopped. This alarm is also displayed with a popup window indicating all pressures. See chapter 7.8.5. Pressure, page 69 and 7.8.8. System Configuration, Standard, page 71. "41 Alarm - Low Work Pressure" Low sample water pressure in the analyzing unit for 10 seconds. It indicates a problem on the inlet side of the analyzing unit or with the sample pump. For an air motor sample pump: Inspect and clean the Exhaust protection,

see drawing CTB10010 sheet 4 of 5, Analyzing unit with air motor sample pump page 117. “RUNNING” mode is stopped. This alarm is also displayed with a popup window indicating all pressures. See chapter 7.8.5. Pressure, page 69 and 7.8.8. System Configuration, Standard, page 71. "42 Alarm - No water in Measuring Cell" The water sensor in the measuring cell has been deactivated for 10 seconds. Indicates a problem with the fresh water or sample water. Relevant valves must be checked. “RUNNING” mode is stopped. This alarm is also displayed with a popup window. "43 Alarm - High Water Pressure" High water pressure in the analyzing unit for 10 seconds. Indicates a problem on the outlet side of the analyzing unit. “RUNNING” mode is stopped. See chapter 7.8.5. Pressure, page 69 and 7.8.8. System Configuration, Standard, page 71.


"44 Alarm - Low Water Pressure" Low water pressure in the analyzing unit for 10 seconds. Indicates a problem on the fresh water supply to the analyzing unit. “RUNNING” mode is stopped. See chapter 7.8.5. Pressure, page 69 and 7.8.8. System Configuration, Standard, page 71. "45 Alarm - Overcurrent" The over-current protection relay in the Converting Unit is activated. The cause for an activated relay could be the sample pump pumping against a closed valve or a clogged pipe. The sample pump itself might be clogged.

Reset the over-current protection relay by pressing the key at the front of the relay. The relay is located to the left in the Converting Unit.

Operating conditions that require frequent and repeated resetting of the over-current relay might harm the sample pump. “RUNNING” mode is stopped. "46 Alarm – High Pump Temperature" The high temperature guard connected to terminals 17 and 18 in the Converting Unit is activated. This indicates a high temperature of the pump shaft seal. Check shaft seal oil refilling. See chapter 9.7. Sample Pump Shaft seal oil refilling page 93. “RUNNING” mode is stopped. “47 Alarm - Indicating Flushing Water”

The unit is in “RUNNING” mode and the “ZD4” input is active. Close the water valve. See chapter 7.8.8. System Configuration, Standard page 71. “RUNNING” mode is stopped.

8.8. Paper Printer alarms The Computer PCB (master) is communicating with the Paper Printer continuously and will give Printer alarm immediately. The unit cannot discharge with one of the paper printer alarms remaining. Press the "Alarm Reset"-key in the "Alarm Table" to reset the alarm and try to fix the fault. See chapter 7.3. Alarm Table, page 53. However, the printer can be deselected in the Setup menu. See chapter 7.8.8. System Configuration, Standard page 71 Printer hardware is RS232 and baudrate is 9600 baud. "50 Alarm – Printer Busy" "51 Alarm – Printer Busy (Xoff)" Printer is busy and do not accept more printouts. Check cable connections to the printer and that printer paper is correctly installed. "52 Alarm – Printer Feedback Error" Wrong format on printer reply. Check cable connections to the printer and its baudrate settings. "53 Alarm – Printer Cover Open" "54 Alarm – Printer Paper End/Cover Open" Printer has no paper or its paper cover is open. Check the printer paper and its cover. "55 Alarm – Printer Head Temp Error" If this alarm remains the printer need to be replaced. "56 Alarm – Printer Voltage Error" If this alarm remains the printer and/or the CUIO PCB connected to the printer need to be replaced. "57 Alarm – Printer Feedback Missing" No reply from Printer. Check cable connections to the printer. "58 Alarm – Printer Buffer Overflow" Printer buffer has overflow. Printer busy do not work, check cable connections to the printer. If this alarm remains the printer and/or the CUIO PCB connected to the printer need to be replaced.


8.9. Extended Converting unit Motor alarms (Optional) "60 Alarm – Sample pump Motor PTC Overheat" High resistance > 1500 Ohm measured on the PTC resistors in the sample pump motor windings. The alarm can be reset when the resistance is < 1250 Ohm. The Converting I/O PCB stops both the sample pump and the space heater. “RUNNING” mode is stopped. "61 Alarm – Sample pump Motor PTC Shortcut" Low resistance < 70 Ohm measured on the PTC resistors in the sample pump motor windings. The alarm can be reset when the resistance is > 80 Ohm. The Converting I/O PCB stops both the sample pump and the space heater. “RUNNING” mode is stopped. "62 Alarm – Sample pump Motor Phase Error" Different current consumption on the different phases of the sample pump motor. The alarm is raised when the lowest current is < 70% of the highest current. The Converting I/O PCB stops the sample pump. “RUNNING” mode is stopped. "63 Alarm – Sample pump Motor Limits" If the unit is in “RUNNING” mode: At least one of the sample pump motor currents is outside its high and low limits. See chapter 7.8.6. Motor page 70. “RUNNING” mode is stopped. If the unit is in “StandBy” mode: At least one of the sample pump motor current is higher than the Standby Max limit. See chapter 7.8.6. Motor page 70. "64 Alarm – Sample pump Motor Heater" Raised in “StandBy” mode only as the heater can only be active in “StandBy” mode. Two consecutive failures to start the heater of the sample pump motor. Check the wiring to the sample pump motor.

The expected resistance between terminals 33 and 34 of the converting unit I/O PCB is 22 Ohm + the resistance of the wiring.

Remember to make the Converting unit powerless before measuring.

8.10. Miscellaneous Sample pump and Overboard Valve alarms. "66 Alarm – Sample Pump Running feedback" IMPORTANT: Verify that the sample pump is not running! Raised in “StandBy” mode if the contactor feedback indicates that the sample pump is running. The feedback contact from the sample pump motor control contactor is open. If the alarm is reset but remaining, it will be activated at every touch screen timeout (about 30 minutes). See chapter 7.8.9. System Configuration, Alarms&Extras page 71 and

drawing CTB110627.1el, internal cable diagram for electrical sample pump motor page 141. It is recommended to monitor this contactor feedback. Keep the Converting unit powerless until the error can be fixed. "67 Alarm – Sample Pump no Running feedback" Raised in “RUNNING” mode if the contactor feedback indicates that the sample pump in not running. The feedback contact from the sample pump motor control contactor is closed. See chapter 7.8.9. System Configuration, Alarms&Extras page 71 and

drawing CTB110627.1el, internal cable diagram for electrical sample pump motor page 141. It is recommended to monitor this contactor feedback. Keep the Converting unit powerless until the error can be fixed. "68 Alarm – Work Pressure after Pump Stop" IMPORTANT: Verify that the sample pump is not running! The work pressure low limit is exceeded 5 seconds after the sample pump was stopped.

A possible reason is that the sample pump is not stopped due to a malfunction in the sample pump control.


"69 Alarm – Freezing risk Measuring cell"

The temperature in the Measuring cell is below 4°C and the water sensor is active. The alarm is raised only once and will not be activated again unless the Measuring cell temperature first has increased above 8 degrees.

Drain the Analyzing unit, see chapter 5.3. Close down procedure page 39. "70 Warning – VALVE OPENED, Line#1" "71 Warning – VALVE OPENED, Line#2" "72 Warning – VALVE OPENED, Line#3" "73 Warning – VALVE OPENED, Line#4"

The overboard valve feedback for the indicated line is active although another line is selected as the active overboard line in the computer menu. Investigate if the valve is open or if the feedback is faulty.

"74 Alarm – Pump Disconnector Switch is ON" Raised in “StandBy” mode if the disconnector feedback indicates the switch in “ON” position. The feedback contact from the disconnector switch contactor is open. The alarm will be activated at every touch screen timeout (about 30 minutes). See chapter 7.8.9. System Configuration, Alarms&Extras page 71. Connect disconnector switch feedback to terminals 13, 14 on the Converting unit I/O pcb. Set the disconnector switch to “OFF” when the unit is not in use. "75 Alarm – Pump Disconnector Switch is OFF" Raised in “RUNNING” mode if the disconnector feedback indicates the switch in “OFF” position. The feedback contact from the disconnector switch contactor is closed. See chapter 7.8.9. System Configuration, Alarms&Extras page 71. Connect disconnector switch feedback to terminals 13, 14 on the Converting unit I/O pcb. Set the disconnector switch to “ON” when the unit is in use.


8.11. Indications on PCB's 8.11.1. Computer unit I/O PCB indications

PCB located in the Computer unit, see CTB10001p sheet 3, Computer Unit with open door page 98, d5. 8.11.2. Converting unit I/O PCB indications

PCB located in the Converting unit, see CTB10003 sheet 3 of 4, Converting Unit page 102, d5.

Buzzer

Modbus Transmit Enable

Modbus Transmit

Modbus Receive

NMEA Receive

VDR Transmit

Overboard valve feedback, EL1

Overboard valve feedback, EL2

Speed log

Spare input

Indicate power and a running program with a flashing diode, 0.5 Hz

Modbus Receive

Modbus Transmit


8.11.3. Extended Converting unit I/O PCB indications (Optional)

PCB located in the Converting unit, see CTB10003 sheet 4 of 4, Converting Unit page 103, d5. 8.11.4. Zener barrier PCB indications

PCB located in the Converting unit, see CTB10003 sheet 3 of 4, Converting Unit page 102, d6.

Modbus Receive

Modbus Transmit

Measuring cell receive

Measuring cell comm. ok

Measuring cell transmit

Indicate power and a running program with a flashing diode, 0.5 Hz

Modbus Receive

Modbus Transmit

Heater Power

Indicate a running program with a flashing diode, 1 Hz


9. Maintenance, Spare parts and Consumables

9.1. Software upgrading The software in the Computer unit can be upgraded via a USB memory stick attached to the USB port at the front of the computer unit. It is recommended to contact an authorized agent for the software upgrade. Three parts are needed for an upgrade:

1. A file containing the software. In the name of the software file the software version, year and day of creation are mentioned. The extension is “.deb”.

2. A particular document, step by step guiding through the upgrade procedure. This document contains a description of the significant changes and might also recommend hardware updates needed to fully take use of the new software.

3. A serial number specific access password which the unit will ask for before the upgrade can take place. This password is normally provided by an authorized agent.

9.2. Battery replacement The Computer unit CPU printed circuit board contains a Lithium battery, type CR1225 3V. For location, see drawing CTB10001p sheet 3, Computer Unit with open door page 98, d4. The battery is powering the Real Time Clock for keeping time when power is switched off to the Computer Unit. A battery failure will affect the Real Time Clock, the Power Off Time and Accumulated Total Oil Discharged. After a battery failure and a power off: Real Time Clock must be set, see chapter 7.9.2. Real Time Clock page 73 Power Off Time on Recorded data (1:st printout after Power On) will be faulty. Accumulated Total Oil Discharged will need a reset, see chapter 7.2.2. Running Settings page 47

9.3. Saving Printouts and Settings on a USB memory stick The recording device is formatted electronically as mentioned in MEPC.108(49) chapter 6.9.1. Recorded data is stored in a non-volatile memory and can hold approximately 3,000,000 printouts. Recorded data can be copied to a USB-memory stick. Refer to chapter 7.1. Main Menu page 45 and chapter 7.5. USB page 56. All settings made to set up the individual CleanTrack can also be saved to a USB memory stick. This backup file named “CTB-####_setup.txt” can be used if the Computer unit CPU card needs to be replaced in the future. The file can then be mailed to [email protected] and be preinstalled on the new CPU card. Refer to chapter 7.1. Main Menu page 45 and chapter 7.5. USB page 56.

9.4. Periodic Checks and Servicing Certain checks and servicing should be carried out at regular intervals in order to minimize the risk for unexpected malfunctions during operation. Below is a maintenance list to be carried out after each use and another list to be carried out at regular intervals of 6 months. After each time of usage:

1. Check that chapter 5.3. Close down procedure page 39 has been followed. 2. If the unit shall not be used for a longer time or sub-zero conditions might arise,

See chapter 5.4. Closing down for a longer time or preserving for sub-zero conditions page 39. 3. Check mounting and cable penetrations of motor to be tightened and in order. 4. Check pump connections and fittings to be tightened and in order 5. Check the installation and the components for signs of leakage. Clean if necessary. 6. If bulkhead mounted sample pump: check the oil level in the sample pump shaft seal.

a. See chapter 9.7. Sample Pump Shaft seal oil refilling page 93. 7. Check that all manually operated sample valves are closed. 8. If paper printer: check the amount of printer paper that is left and replace the roll if necessary, for safeguarding

uninterrupted operation during next discharge. 9. Consider to store “Recorded data” on a USB-memory stick. See chapter 7.5.1. USB-Memory stick page 56.

mailto:[email protected]


Every 6 months: 1. Inspect the interior of all cabinets for general condition and cleanliness. 2. Check all components with respect to mounting, clamping of cables, and any signs of damage. 3. Check all connections to be tightened and not leaking. 4. Check the cables to the analyzing unit and sample pump along their entire length with respect to any signs of

chafe, wear or other damage and the bulkhead penetrations to be in proper conditions. 5. Check the sample pump:

If sample pump SPP-100 with Ex motor: See Sample pump SPP-100 with Explosion proof electric motor page 12.

1. Check the setting of the sample pump. In chapter 7.8.8. System Configuration, Standard page 71 verify that the setting of property “Sample Pump” is “Suzhong SPP-100”.

2. Refer to makers MAINTENANCE part in chapter 12.8.1. Elprom instructions page 201 If sample pump is bulkhead mounted:

See Sample pump Nikuni 32MED22/Matre P06 for Bulkhead mounting page 12 1. Check the setting of the sample pump. In chapter 7.8.8. System Configuration, Standard page 71

verify that the setting of property “Sample Pump” is “Nikuni 32MED22” or “Matre P06”. 2. Check the oil level in the sample pump shaft seal.

See chapter 9.7. Sample Pump Shaft seal oil refilling page 93 If sample pump with air motor:

See Sample pump Speck Y-2951 with Air driven Gast motor page 12. 1. Check that all air supply valves to the air motor are closed. 2. Refer to makers MAINTENANCE part in chapter 12.9. Sample Pump, Speck pump with Gast air

motor page 228. 6. For upgraded units with serial numbers earlier than CTB 2892 and with electrical sample pump motors:

Check that the sample pump motor contactor feedback is wired and enabled. See chapter 7.8.9. System Configuration, Alarms&Extras page 71 and the setting of the property “ConvertingUnitType” is “PumpFeedback”.

7. In case of computer or converting unit malfunction: See chapter 8.1. Malfunction of Computer/Converting unit page 82.

9.5. Verification of accuracy and access to restricted parts User access to the Measuring cell is restricted with seals, which only Brannstrom Sweden AB can replace, in order to comply with clause 5.1 of MEPC. 108(49). A calibration certificate is issued by Brannstrom Sweden AB when the CleanTrack 1000B is new. Later on, an “Accuracy Verification Certificate” can only be issued by Brannstrom Sweden AB or its approved agents. The validity of the calibration certificate is max 5 years. Once the factory issued calibration certificate has expired the measuring cell must be replaced. The calibration certificate should be retained on board for inspection purpose.

9.6. Cleaning of Inlet Filter When CleanTrack 1000B is in “StandBy” mode, close the sample inlet probe valves, open the drain valve and close the Analyzing unit inlet valve. Remove and clean the filter screen. Usage of CleanTrack 1000B sample pump unit without the inlet filter screen could harm the sample pump. The Inlet Filter is item 15 in drawing 10.9.1. Partnames of typical arrangement page 129.

9.7. Sample Pump Shaft seal oil refilling This part does only apply to CleanTrack 1000B versions with bulkhead penetration sample feed pumps. The oil reservoir is positioned in the engine room side. Remove the oil reservoir cover nut. Be careful not to unscrew the reservoir from the pump. Refill up to the thread with recommended oil type. Be careful not to harm the plastic reservoir when the cover nut is mounted. Turn the cover nut Clock Wise until it is in right position. See chapter 10.5. Nikuni Sample pump for Bulkhead mounting page 121 or chapter 10.6. Matre Sample pump for Bulkhead mounting page 124.


9.8. Spare parts 9.8.1. Computer Unit

• Computer CPU PCB CTB10001p sheet 3, Computer Unit with open door page 98, item d6. • LCD screen • Touch panel • Power supply unit CTB10001p sheet 3, Computer Unit with open door page 98, d1 • Computer unit I/O PCB CTB10001p sheet 3, Computer Unit with open door page 98, d5 • Paper printer (optional) CTB10001p sheet 3, Computer Unit with open door page 98, d2 • Paper rewinder (optional) CTB10001p sheet 3, Computer Unit with open door page 98, d3

9.8.2. Converting Unit

• Converting Unit PCB CTB10003 sheet 3 of 4, Converting Unit page 102, d5 • Zener Barrier PCB CTB10003 sheet 3 of 4, Converting Unit page 102, d6

See chapter 4.9. Zener Barrier Instructions and Replacement page 25 • Pump relay CTB10003 sheet 3 of 4, Converting Unit page 102, d2 • Overcurrent relay See current limits for different Sample pumps below. • Transformer CTB10003 sheet 3 of 4, Converting Unit page 102, d4

9.8.3. Analyzing Unit

• Measuring Cell CTB10010 sheet 5 of 5, Analyzing unit with air motor sample pump page 118,d2

See chapter 4.10. Measuring Cell Instructions and Replacement page 30 • Pressure transmitter CTB10010 sheet 5 of 5, Analyzing unit with air motor sample pump

page 118,d4 9.8.4. Sample pump 9.8.4.1. Ex. motor Sample pump, SPP-100 Note that it is not allowed for unauthorized personnel to do any repair work on the motor. Refer to makers MAINTENANCE AND REPAIR part in chapter 12.8.1. Elprom instructions page 201.

• Seal kit for sample pump. • Overcurrent relay, 1-1.6A CTB10003 sheet 3 of 4, Converting Unit page 102, d1

9.8.4.2. Bulkhead mounted Sample pump, Nikuni 32MED22

• Seal kit for sample pump. • Overcurrent relay, 4-6A CTB10003 sheet 3 of 4, Converting Unit page 102, d1

9.8.4.3. Bulkhead mounted Sample pump, Matre P06

• Seal kit for sample pump. • Overcurrent relay, 4-6A CTB10003 sheet 3 of 4, Converting Unit page 102, d1

9.8.4.4. Air motor Sample pump, Speck Y2951

• Pressure gauge. CTB10010 sheet 5 of 5, Analyzing unit with air motor sample pump page 118,d6

• Seal kit for sample pump. 9.8.5. Fuses Power Supply Unit, see drawing CTB10001p sheet 3, Computer Unit with open door page 98, d1.

• Fuse F1, T1A, Subminiature 8.5mm Time-Lag T, 250VAC, Schurter 0034.6615 • Fuse F2, T1A, Subminiature 8.5mm Time-Lag T, 250VAC, Schurter 0034.6915 • Fuse F3, T1A, Subminiature 8.5mm Time-Lag T, 250VAC, Schurter 0034.6915 • Fuse F4, T1A, Subminiature 8.5mm Time-Lag T, 250VAC, Schurter 0034.6915


• Fuse F5, T1A, Subminiature 8.5mm Time,-Lag T,250VAC, Schurter 0034.6915 “Standard” Converting Unit PCB - BE382C, see drawing CTB10003 sheet 3 of 4, Converting Unit page 102, d5.

• Fuse F1, T500mA, Tube 5x20mm, Time-Lag T, 250VAC • Fuse F2, T3.15A, Tube 5x20mm, Time-Lag T, 250VAC • Fuse F3, T1A, Tube 5x20mm, Time-Lag T, 250VAC • Fuse F4, T1A, Tube 5x20mm, Time-Lag T, 250VAC

“Extended” Converting Unit PCB - BE450B, see drawing CTB10003 sheet 4 of 4, Converting Unit page 103, d5. • Fuse F11, T3.15A, Tube 5x20mm, Time-Lag T, 250VAC • Fuse F12, T2A, Tube 5x20mm, Time-Lag T, 250VAC • Fuse F13, F1,25AH, Tube 5x20mm, IR 1500A/250VAC • Fuse F14, F1,25AH, Tube 5x20mm, IR 1500A/250VAC • Fuse F15, F1,25AH, Tube 5x20mm, IR 1500A/250VAC

Zener Barrier PCB, BE381C, see drawing CTB10003 sheet 3 of 4, Converting Unit page 102, d6.

• Fuse F5, T315mA, Tube 5x20mm, Time-Lag T, 250VAC • IMPORTANT: 3 x fuses inside lid must be of approved types printed on the lid of the zener barrier pcb.

When creating this document, Revision 2.20x, the 2 types are: Littelfuse 217.063, 63 mA Quick Blow, 250VAC Schurter FSF 0034.1530, 63 mA Quick Blow, 250VAC For instructions, see chapter 4.9. Zener Barrier Instructions and Replacement page 25.

9.9. Recommended Spare parts

• 1 set of fuses: 1 pc T315mA, Tube 5x20mm, Time-Lag T, 250VAC 1 pc T500mA, Tube 5x20mm, Time-Lag T, 250VAC 1 pc T1A, Tube 5x20mm, Time-Lag T, 250VAC 1 pc T3.15A, Tube 5x20mm, Time-Lag T, 250VAC 2 pcs 63 mA according to chapter 9.8.5. Fuses page 94. 2 pcs T1A, Subminiature 8.5mm Time-Lag T, 250VAC, Schurter 0034.6915

• 2 pcs cleaning brush for cleaning of glass pipe in Measuring Cell.

If Extended converting unit (optional) • 1 extra set of fuses:

1 pc T2A, Tube 5x20mm, Time-Lag T, 250VAC 4 pcs F1,25AH, Tube 5x20mm, IR 1500A/250VAC

9.10. Consumables Lithium Battery The Computer unit CPU printed circuit board contains a Lithium battery, type CR1225 3V. See chapter 9.2. Battery replacement page 92. Paper Printer Roll (optional) The paper shall fit to printer: Custom PCPLUS II-S2B. Printer manage thermal roll paper with heat-sensitive side on outside of roll. Paper roll width: max 58 mm. Paper roll diameter: max 50 mm. Cleaning Brush Cleaning brush for CleanTrack 1000 B (cleaning of glass pipe in Measuring Cell).

9.11. Storage before installation Prior to installation the unit should be stored in a tempered and dry location protected from sunlight.


10. Figures and Drawings This chapter contains standard drawing alternatives and options. For project specific drawings, refer to chapter 14. Project specific drawings and data sheet page 231. The rest of the page is intentionally left blank.


10.1. Computer Unit Drawing: CTB10030 sheet 1, Computer Unit mounting


Drawing: CTB10001p sheet 3, Computer Unit with open door. Note: printer is optional. Standard version is without items d2 and d3.


Drawing: P3715090 sheet 1, Computer Unit panel mount instructions.


10.2. Converting Unit Drawing: CTB10003 sheet 1 of 4, Converting Unit.


Drawing: CTB10003 sheet 2 of 4, Converting Unit.






10.3. Analyzing Unit 10.3.1. Analyzing Unit skid with Ex. motor Sample pump Drawing: CTB10015 sheet 1 of 3, Analyzing unit skid with electrical Ex. motor sample pump.


Drawing: CTB10015 sheet 2 of 3, Analyzing unit skid with electrical Ex. motor sample pump.


Drawing: CTB10015 sheet 3 of 3, Analyzing unit skid with electrical Ex. motor sample pump.


10.3.2. Analyzing Unit with external Sample pump Drawing: CTB10014 sheet 1 of 5, Analyzing unit with external sample pump.


Drawing: CTB10014 sheet 2 of 5, Analyzing unit with external sample pump.








10.3.3. Analyzing Unit with Freestanding items for External Sample pump



10.3.4. Analyzing Unit with Air motor Sample pump Drawing: CTB10010 sheet 1 of 5, Analyzing unit with air motor sample pump.


Drawing: CTB10010 sheet 2 of 5, Analyzing unit with air motor sample pump.








10.4. SPP-100 Sample pump with Ex. Motor



10.5. Nikuni Sample pump for Bulkhead mounting Drawing: CT041029.1, Nikuni Bulkhead Sample pump.




10.6. Matre Sample pump for Bulkhead mounting Drawing: CT891211.1, Matre Bulkhead Sample pump.


Drawing: CT900907.1, Matre Bulkhead Sample pump.


10.7. Connection box Drawing: CTB10021 sheet 1 of 2, Connection box.


Drawing: CTB10021 sheet 2 of 2, Connection box


10.8. Measuring Cell replacement Drawing: CTB10032 sheet 1 of 1, Measuring Cell replacement. For replacement instructions, see chapter 4.10. Measuring Cell Instructions and Replacement page 30.


10.9. GA-plans 10.9.1. Partnames of typical arrangement Drawing: CTB10601 sheet 1 of 1, Partnames of typical arrangement.


10.9.2. GA-plan with Ex. motor Sample pump Drawing: CTB10907 sheet 1 of 1, GA-plan with skid Ex. motor sample pump.


Drawing: CTB10917 sheet 1 of 1, GA-plan with skid Ex. motor sample pump and flushing.


Drawing: CTB10908 sheet 1of 1, GA plan with free standing Ex. Motor sample pump.


10.9.3. GA-plan with bulkhead penetrating Sample pump Drawing: CTB10906 sheet 1 of 1, GA-plan with bulkhead penetrating Sample pump.


Drawing: CTB10916 sheet 1 of 1, GA-plan with bulkhead penetrating Sample pump and flushing.


10.9.4. GA-plan with Air motor Sample pump Drawing: CTB10901 sheet 1 of 1, GA-plan with air motor sample pump.


Drawing: CTB10911 sheet 1 of 1, GA-plan with air motor Sample pump and flushing.


10.9.5. GA-plan with pilot-controlled Air motor Sample pump Drawing: CTB10903 sheet 1 of 1, GA-plan with pilot-controlled air motor sample pump.


10.10. Electrical 10.10.1. Electrical cable diagram for electrical Ex. motor sample pump Drawing: CTB110204.1el, electrical cable diagram for electrical Ex. motor sample pump.


10.10.2. Electrical cable diagram for bulkhead mounted sample pump Drawing: CTB110204.1bh, electrical cable diagram for bulkhead mounted sample pump.


10.10.3. Electrical cable diagram for air motor sample pump Drawing: CTB110204.1pn, electrical cable diagram for air motor sample pump.


10.10.4. Internal cable diagram for electrical sample pump motor Drawing: CTB110627.1el, internal cable diagram for electrical sample pump motor.

Include wires 008 and 009 for

sample pump contactor feedback.


10.10.5. Internal cable diagram for Extended SPP-100 sample pump motor (Optional) Drawing: CTB110627.1elext, internal cable diagram for optional extended SPP-100 sample pump motor


10.11. Sample probes 10.11.1. Sample probes installation arrangements 1” Drawing: CTB891216.1, Sample probes installation arrangements 1”.


Drawing: CTB900105.4, Sample probes valve arrangements 1”.


10.12. Flow meter Drawing: CT891215.5, CleanTrack Flow meter unit, Vertical.


Drawing: CT900503.1, CleanTrack Flow meter unit, Horizontal.


Drawing: CT050505.1, CleanTrack Flow transmitter bracket.


11. Approval Certificates 11.1. Certificate: MED-D



11.2. Type Approval, DNV





11.3. Type Approval, Germany





11.4. IMO Certificate, CCS



11.5. Type Approval, CCS




11.6. Type Approval, NK


11.7. Type Approval, RMRS



12. ATEX Certificates and Instructions 12.1. Declaration of Conformity




12.2. ATEX Certificate Zener Barrier PCB






12.3. ATEX Certificate Measuring Cell





12.4. Pressure transmitter, Danfoss








12.5. Pressure transmitter, Siemens 12.5.1. Declaration of Conformity



12.5.2. ATEX Certificate




12.6. Flow meter, Siemens









12.7. Flow meter, Fuji




12.8. Sample Pump, SPP-100 with Elprom explosion proof motor 12.8.1. Elprom instructions





12.8.2. Elprom Certificate, EPT 17 ATEX 2588 X





12.8.3. Elprom Certificate, EUM1 10 ATEX 0350


















12.8.4. Hummel Cable Gland Certificate, DEKRA 12ATEX0139 X



12.9. Sample Pump, Speck pump with Gast air motor Please contact Brannstrom Sweden AB to receive the ATEX certificate of the Speck sample pump with Gast air motor. Email: [email protected]

mailto:[email protected]


13. Appendix, Work shop test and Calibration Certificate The 4 following pages contains: Work shop test: 4 pages Calibration Certificate: 1 page


This page is intentionally left blank.


14. Project specific drawings and data sheets


This page is intentionally left blank.

CleanTrack 1000 B - Manual - Insatech Marine

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